Maintenance & Technical > KX500 Original

KX450F Forged Brake Lever On 91' 500

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Bsock:
Been around haven't posted anything figure some people may find this useful.  This is so far my process in getting a KX450F Troque1 pedal on my 91' 500.  KX Sandblaster spiked my interest on YouTube thanks.  I have no idea if this is even going to work this is just an idea with pictures.  Hope I put this in the proper place also.
Brandon

First is a shot of the lever very nice piece in my opinion.


Next is a few pics side by side stock and the new fella.




Up close of the sealed bearings I will be removing since they are not the correct ID.


After doing some measuring and what not here are the dimensions I came up for my fantasy bushings.


Pictures of the bearing and sleeve I removed from the new lever.




My fantasy bushings made from bronze.  I was going to use sealed bearings again but with keeping the OD the same and needing to open the ID there is not enough room for bearings and a cage.


Installed in the new lever I also used green retaining compound before I pressed them in if anyone was curious....


Some pics of the lever on the bike, still a bit to go to see how this is gonna work out I'll do my best to try and keep this updated. 

alward25:
That looks great!

sandblaster:
Lol... Yeah, That brand of rear brake pedal uses a oddball bearing size.
I had to make special bushings for mine as well.
The KX250F Hammerhead I used on another bike was a lot easier because the bearing sizes are different and I simply ordered the bushings and pressed them in.
Yours is looking great!

Stock KX250F rear brake lever... Hammerhead clevis



KX250F off brand (China) rear brake lever and a Hammerhead clevis

Bsock:
Awesome I figured you had to be lurking somewhere on here Sandblaster!  Thanks again for the P/N on the clevis kit.
Brandon

JRRacing:
please share that part#

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