Broken brake and clutch levers - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 14 Old 08-08-2017, 04:08 PM Thread Starter
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Join Date: Apr 2017
Location: Spain and Gibraltar
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Broken brake and clutch levers

I had just replaced a broken brake lever and got the bike looking "Ship Shape and Bristol fashion" and started riding up our driveway when our daft Dalmatian dog stopped in front of the bike.
I stopped but could not hold the bike on the hill and dropped it. the result was the new brake lever broke just below the end knob.
Rather than buy another lever I drilled through the knob then just over 3cms. into the brake lever. The brake lever I threaded with an M4 tap and opened and countersunk the hole through the brake lever knob.

The next step was to bolt the two pieces together using Nural 27 as the thread locker. The recessed bolt head and join were sanded down and sprayed satin black
The result was a better than new die-cast brake lever now reinforced with a threaded steel pin.

James.
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post #2 of 14 Old 08-08-2017, 04:52 PM
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Nice MacGyver move!

Otherwise . . . proper HANDGUARDS, with their metal skeletons, do a fair job of protecting not only hands but clutch and brake levers also . . .
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post #3 of 14 Old 08-08-2017, 06:17 PM
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So you didn't have any Duct Tape?
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post #4 of 14 Old 08-09-2017, 06:08 AM Thread Starter
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Originally Posted by Bluehighways View Post
So you didn't have any Duct Tape?
No, I'm saving that for when my universal tank bag with magnets arrives

Damocles Do you have a link as to where I can get these proper handguards?
My bike just has the standard (blue) plastic handguards.

James.
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post #5 of 14 Old 08-09-2017, 09:23 AM
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Originally Posted by Trail Bike Rider View Post
No, I'm saving that for when my universal tank bag with magnets arrives

Damocles Do you have a link as to where I can get these proper handguards?
My bike just has the standard (blue) plastic handguards.

James.
Best buy, in my opinion, Tusk handguards with spoilers:

https://www.rockymountainatvmc.com/p...-with-Spoilers

(Note: I had to use Chrome to access above link; Windows 8.1 wouldn't cut it.)

Fit KLRs; replacement spoilers cost about $ 12/pair in case of road rash.

Last edited by Damocles; 08-09-2017 at 09:28 AM.
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post #6 of 14 Old 08-09-2017, 12:24 PM Thread Starter
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Originally Posted by Damocles View Post
Best buy, in my opinion, Tusk handguards with spoilers:

https://www.rockymountainatvmc.com/p...-with-Spoilers

(Note: I had to use Chrome to access above link; Windows 8.1 wouldn't cut it.)

Fit KLRs; replacement spoilers cost about $ 12/pair in case of road rash.
Thanks for that!. I accessed the site easily with chrome and running Win 10.

Very nice handguards but as usual when I put in my Spanish address the handguards and spoilers etc. came to around $200Usd with shipping and taxes. Remember too when parcels from outside the EU arrive I have to pay another 21% plus "administration" import Taxes
If it weren't for these money grubbing extra costs I would buy them in an instant.

Here at my Spanish home I have a fully fitted machine workshop, Lathe, milling machine, drill press, Mig/Mag welder, plasma cutter etc.
Anodised aluminium bar here is very cheap and available so I will make up some handguards loosely based on those on that web-site, and probably incorporate the stock KLR blue hand shields.

James.
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post #7 of 14 Old 08-09-2017, 12:38 PM
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I like creative ways to solve problems.

You might consider using a firm but not overly tight adjustment on the clamp at the handlebar. Just so that the lever can rotate instead of breaking when forced.
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post #8 of 14 Old 08-09-2017, 01:09 PM
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Not sure if the company CycleGear has an international presence. Their Website doesn't list anything outside of the US; but you might contact them and see. Anyhow,when I needed a set of Hand Guards, Rocky Mountain ATV was out of the Tusk versions, so I acquired the "TrackSide" versions from CycleGear for $49.99 USD. https://www.cyclegear.com/parts/trac...t-with-shields

Last edited by Bluehighways; 08-31-2018 at 01:21 AM.
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post #9 of 14 Old 08-09-2017, 02:32 PM
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Originally Posted by GoMotor View Post
I like creative ways to solve problems.

You might consider using a firm but not overly tight adjustment on the clamp at the handlebar. Just so that the lever can rotate instead of breaking when forced.
On our race bikes we'd put a couple wraps of teflon tape under the mount and then tighten as normal; good chance it'd stay put until a crash. .....still no replacement for decent handguards though IMO.

Dave
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post #10 of 14 Old 08-09-2017, 02:36 PM Thread Starter
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Quote:
Originally Posted by GoMotor View Post
I like creative ways to solve problems.

You might consider using a firm but not overly tight adjustment on the clamp at the handlebar. Just so that the lever can rotate instead of breaking when forced.
Over the years I've saved probably thousands by repairing and re-manufacturing parts for cars and electrical implements.
I started out as a Radio and TV engineer but found that mechanical issues seemed to be second nature. Most of this I put down to the excellent school I attended in the UK that as well as academic subjects such as mathematics, physics and chemistry, also included technical drawing, woodwork and metalwork.

Now after quite a few years since riding my KLR I'll get into the habit of not dropping it
As I mentioned in another post, it's like getting together again with an old girlfriend, so I'm hoping that she remembers that I always treated her well!

James.
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