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.