Brake pedals wearing out my covers...

[Hillclimb#42]

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?

[DoldGuy]

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.

[KX500freak]

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

[tharden]

Like what kx500freak said, brass bushings will cure a lot of problems.

[Polar-Bus]

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..

[Bigtim]

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.

[KXTC]

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.

[Hillclimb#42]

 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?

[Bigtim]

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

[Larry Wiechman]

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.

[bigborefan]

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.