2003 KX 250 SF Conversion rear brake lever replacement

[Sandblaster]

Here is a cool mod from Umberto over at KX Riders

It's kind of a gloomy day in OKC today, so I figured I would try a project I have been putting off for a little bit. I would like to have a little bit longer brake lever, but I couldn't find one specifically for my bike. I was able to fit a Tusk lever to my 2004 KX250 (using the 2004 pivot bolt), but it hits the clutch cover a little bit and sticks out a tad more than I would like.

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Thankfully Tusk makes replaceable ends that you can buy for $19.99. They bolt on to the Tusk lever, but will not bolt to the stock lever without modification.
I also picked up the replacement clevis for $12.99. It says it only fits the 2005 and up, but it fits my 2003 and 2004 just fine.

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[Sandblaster]

In order to get it to fit, I got out my Dremel tool and cut a small trench in the top of the lever to fit a small ridge machined into the bottom of the Tusk lever. Nothing fancy, just ground until the bolt hole lined up.

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I polished the lever up with some Mother's Mag and Aluminum polish, gave it a quick wax and installed it on the bike. I really like how it turned out.

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[Sandblaster]

It gives me the that little bit of extra length I was looking for as well. Here it is with the lever from my 04.

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[Sandblaster]

Very nice... Thanks Umberto

[Umberto]

Thank you Sandblaster! I was inspired by your work adapting the 450 lever to the KX500. Before that I was blind to how crappy the stock brake pedal is.