Fixing a KX500 rear brake lever

[Sandblaster]

I have 6 KX500 rear brake levers in inventory.
Every one of them has the same issue.

2000 kx500 kawasaki rear brake lever mod oem-cycle.com 101.JPG (400.43 KiB) Viewed 6089 times

The attachment point for the master cylinder gets wallered out and make for a sloppy rear brake

I'm gonna fix mine once and for all...

[foxx4Beaver]

funny, my buddy that made my drain plug and I were just discussing this topic in his garage last weekend.
he works as a machinist, and plans on making a stainless steel press-in collar to try.
and if it doesn't work out like he thinks/hopes, he's got another plan.

[Sandblaster]

Yep.... I also considered doing that as it would work just fine.
But, I'm going to try something a little different

Kinda goes along with my personality

[Sandblaster]

Fixed!

KX500 REAR BRAKE LEVER FIXED 101.JPG (109.36 KiB) Viewed 6082 times

KX500 REAR BRAKE LEVER FIXED 102.JPG (47.45 KiB) Viewed 6082 times

KX500 REAR BRAKE LEVER FIXED 103.JPG (55.32 KiB) Viewed 6082 times

[Sandblaster]

To fix it I drilled out the existing hole to make it round again.
Then I cleaned it extremely good.
Next, my welder filled in the hole and added a bit of material around the outside edge where the bearing is as it would be a little too small for the bearing to fit.
Then I drilled a 16mm hole for the bearing.
Slipped the bearing in with a bit of bearing retainer.
DONE!

Oh! Bearing size:
16mm OD x 8mm ID x 5mm wide

Next I need to give it a good ride and see how it holds up.