Author Topic: Brake pedals wearing out my covers...  (Read 2677 times)

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Offline Hillclimb#42

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Brake pedals wearing out my covers...
« on: August 23, 2009, 11:49:12 PM »
I am fighting with the 250 and the 500. The Spring pulls the the pedal over into the clutch cover. At first its nothing, but scratches, but now I'm wearing a groove in both of them. Have you guys had this going on? Found a cure? Will new pedals solve it?

Offline DoldGuy

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Re: Brake pedals wearing out my covers...
« Reply #1 on: August 24, 2009, 04:45:59 AM »
New pedals will cure this until the bushing wears out again. Small details like removing the pedal & cleaning all the grit out & a light coat of grease drastically increases the life of such parts & keeps the bike feeling tight.
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Offline KX500freak

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Re: Brake pedals wearing out my covers...
« Reply #2 on: August 24, 2009, 06:10:41 AM »
most of the time,the pedal connnection to the rear-brakepump tends to wear .
then you can move the pedal up and down without activating the brakepump.
i solved it by making the oval wearhole a round one and fit a homemade bushing in it
i did it with 2 out 3 k5,s ,never issues with that again,it this your issue too ?
or am i talking bout another thing
Dutch Team Green 91-94-01 KX500

Offline tharden

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Re: Brake pedals wearing out my covers...
« Reply #3 on: August 25, 2009, 11:00:00 AM »
Like what kx500freak said, brass bushings will cure a lot of problems.

Offline Polar-Bus

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Re: Brake pedals wearing out my covers...
« Reply #4 on: August 26, 2009, 04:14:50 AM »
Heat the brake lever up with propane, and "tweak" the lever outward for more clearence.

PS: Only do the "heat and bend" method ONCE, or you will make the lever too brittle, and could easily snap..
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Offline Bigtim

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Re: Brake pedals wearing out my covers...
« Reply #5 on: August 26, 2009, 09:44:24 AM »
i have the same problem, i wraped a few thick gauge ziptyes around the part that rubs cover and at least its plastic rubbing metal instead of metal on metal.  alum will only bend 1nce if u are lucky. i didnt want to risk braking another pedal.  lazybones, trackside repair style. :-o

Offline KXTC

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Re: Brake pedals wearing out my covers...
« Reply #6 on: August 29, 2009, 12:42:03 AM »
i solved it by making the oval wearhole a round one and fit a homemade bushing in it

I had the same problem and fixed it the same way. But you need access to (someone with) a lathe. 10 minute job to machine. If you really get stuck PM me with required (vernier) sizes and I can post it over / no problems.

Bigtim said:
i have the same problem, i wraped a few thick gauge ziptyes around the part that rubs cover and at least its plastic rubbing metal instead of metal on metal.  alum will only bend 1nce if u are lucky. i didnt want to risk braking another pedal.  lazybones, trackside repair style.

I wish I thought of that...I waited a bit too long to bush it.
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Offline Hillclimb#42

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Re: Brake pedals wearing out my covers...
« Reply #7 on: August 29, 2009, 01:54:59 AM »
 Wish I had the means to machine out a bushing. I get thousands of zip-tyes, so that will have to do for now. Thanks Big Tim, very good idea. Yet another use for the almighty zip-tye. New pedals are on the way, but they will have to stay in the box until I get new Clutch covers. Are you making them yet JFAB?

Offline Bigtim

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Re: Brake pedals wearing out my covers...
« Reply #8 on: October 04, 2009, 01:22:09 PM »
stoked that my idea got cred not dogged on for being cheap and lazy. Not everybody has access to the right tools for the job.....like a lathe

Offline Larry Wiechman

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Re: Brake pedals wearing out my covers...
« Reply #9 on: October 04, 2009, 02:43:02 PM »
The KDX200's have the same problem. Sealing them with O-Rings and adding a grease zerk made them live on enduro bikes. It's been a while since I put a bushing in one of them and I don't remember the dimensions. I'll do the brake pedal on my 500 as preventive maintenance, take some photos, and post the info.

Offline bigborefan

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Re: Brake pedals wearing out my covers...
« Reply #10 on: October 27, 2009, 12:07:17 PM »
I always took mine to a machine shop and they pressed in a new bushing. I cleaned and greased it almost every ride as well. A little rubber strip zip tied to it helps as well.
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