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XR600R brake lever pivot wear - poss solution

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Greetings all. i have a front and rear disc brake XRR. the lever for the rear brake is sloppy in the frame. that is to say the pivot is wearing and i keep having to adjust the pushrod to get the pedal feel/action the way i like it. i believe this topic has come up before. so i am going to provide a solution to be shared among TT members. in looking at my bike, i find the pivot pin on the brake lever to show almost no wear - there is a small wear mark that measures about 0.005. but it just a tiny divot. all the wear on my bike seems to be to the frame portion of the pivot.

so... i have ordered samples of a bushing (spec's here : http://www.igus.com/wpck/default.aspx?Pagename=iglidur_m250_Werkstoffdaten) and i am going to drill my frame and then set up a reamer to do the finish work on the hole. i may make up a jig to assist in the initial drilling process. if it all works as planned, i will then offer up the jig, a sharp drill bit, the correctly sized reamer, and a pair of the bushings. cost will be $2.50 plus shipping.

maybe we can set this up like a vine where a bunch of folks sign up and i put them in some order and the box of tools and a bunch of bushing gets shippied from one TT member to the next until everybody is all fixed up.

thoughts and comments welcome.

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Mine is so wasted I have also begun seriously thinking about doing something like you describe.

Let me know how this project progresses.

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I put a bunch of $0.54 McMaster bronze bushings in Tusk $6.00 front brake levers to make them a nice, non-wiggly fit on the pivot bolt. Worked really well.

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I've been putting off repairing the frame pivot on my XR because the fix would entail stripping the frame and jigging it in a Bridgeport. If you can make a small jig which locates a few points along the frame and can maintain the center line and concentricity of a repair hole, it would be a huge help.

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