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Post Info TOPIC: brake pedal modification for street use
ago


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brake pedal modification for street use
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I ride on road only and didn't like the tiny little rabbit trap brake pedal on my 2011 model ttr250 so I decided to modify the original.

get a piece of 25x50x3mm aluminium extrusion and a piece of propeller plate [ checker plate] 50x80mm thinnest available. get a piece of box section steel tube that is the same inside height  [ 19mm] as the extrusion[possibly stainless] and also 80mm long. 

using an angle grinder VERY carefully grind down the top of the pedal till it's a tight fit inside the steel tube. having prepainted the tube to stop rust slide it over the ground down repainted pedal and then slide the extrusion over it, use a soft faced mallet if it's tight and hit it on right up against the brake pedal lever.

with it all centred in the extrusion drill a small hole right through the assembly and original pedal so as to be able to pass a stainless button head machine screw say 5-6 mm completely through with enough left to screw a stainless nyloc nut on and then some protruding. get your propeller plate and glue and clamp it to the top of the extrusion then drill up through the already predrilled hole in the base of your pedal.

countersink the hole on the top and install the machine screw and tighten the nyloc underneath using threadlocker as well [ you don't want the pedal falling off ] at the other end and in line with the inner fastener drill and tap a suitable hole from underneath and screw your other loctited fastener up into the steel tube lower surface only, you may be able to get a nyloc on but there's not a lot of room. 

to finish the job off you can buy a standard size black plastic cap that is usually fitted to furniture square tubing of the same size as our new pedal uses. buy one before you get the steel section then you will know it fits properly. how far in the cap goes will decide where your outer fastener screws in. looks the goods and you'll wonder why you can't buy one off the shelf. unless your " THE DOCTOR" you won't ground it.furious



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Sounds interesting

Photo please !



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2004 TTR250 - Highway Dirtbike Hand Guards, 38mm Bar Risers, D606 Front & Rear, Opened up Airbox with Twin Air Filter, Re-jetted Carby, B+B Bash Plate & Frame Guards, DIY 3mm Alloy Tail Tidy, 14/47 Gearing.

 

ago


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Posts: 31
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sorry bm steve I have not advanced to the online photo stage yet but I do own a digital video camera which I will get someone to show me how to download onto this site sometime. I also don't have a smart phone as yet.

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