Stripped pinch bolt - rear brake lever - Kawasaki KLR 650 Forum
How To's & Tech Guides Post your mod how to's and tech guides here. Topics will be locked only to allow editing by original author.

LinkBack Thread Tools Display Modes
post #1 of 1 Old 08-07-2019, 02:28 AM Thread Starter
1st Gear
Schoen's Avatar
Join Date: Aug 2019
Location: Seattle, WA
Posts: 54
Stripped pinch bolt - rear brake lever

Picked up a heavily loved '08 (CA model), my first dual sport. Previous owner had a bunch of dried glue covering the pivot point of the rear brake lever, said he broke the bolt but, so long as the bolt stayed in place, the lever was functional (hence the glue). I decided to make that my first project. Picked off the glue, pulled the bolt out. It wasn't broke, just stripped. And if the steel bolt was stripped, I figured the aluminum threads inside were worse. Dealer wanted $146 for a new brake lever and bolt (that was with their nice-guy 15% off discount). And I didn't want to take my chances on a used brake lever from Ebay (I already have a used one). So...

I took the stripped bolt to Home Depot and measured it (I think it was 10mm). Found that a 1/4" bolt is just a tad larger than that. Bought one for 46 cents. Borrowed a 1/4" tap from my buddy, cut new threads in the brake lever. Added a lock washer and screwed in my 46 cent 1/4" bolt. And that's that. Probably should have added some loctite. Maybe if it ever falls out, but I doubt it will with the lock washer.

Next potential project: either decalifornicating it, or figuring out what happens if I scrape off the silicone glue from the engine case gasket edges (and learning why someone would put glue on an engine case right after a 685 kit was installed - like I said, heavily loved).

Last edited by Schoen; 08-07-2019 at 03:07 AM.
Schoen is offline  
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome