Brake Lever ???

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KDX4ID
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Brake Lever ???

Post by KDX4ID »

I'm having an issue replacing my front brake lever on my 2005 KDX220.

Kawi dealer and all the fiche I can find on the net show one style of lever yet my bike has another.

Any thoughts?


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gregp
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Post by gregp »

That master cylinder looks stock, but the push rod does not. You should be able to go back to a stock lever, and modify that rod to work. That rod just pulls out of the rubber boot.
2004 Dual Sported KDX200
1999 Ninja 250 (Daughter's)
1996 DR 650 (stock, mostly street use)
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KDX4ID
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Post by KDX4ID »

>|<>QBB<
gregp wrote:That master cylinder looks stock, but the push rod does not. You should be able to go back to a stock lever, and modify that rod to work. That rod just pulls out of the rubber boot.
I've tried to pull that rod out and it won't go. I'm afraid to pull to hard as to damage things.

I too think master cylinder is stock, as the former owner was not the type that would replace such things and she was the orininal owner. When I bought the bike it had the "greenie handgaurds" in place and looked very stock.

Should I just yank on that rod?
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1996 Honda 650L... GONE but not forgotten
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scheckaet
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Post by scheckaet »

slow down there buster, u can't yank it out just like that. The is a circlip behind the rubber piece holding the rod, just pry it out slowly so you don't damage the rubber. you''ll see the circlip inside holding the rod to the master cylinder. Looks like the po didn't bleed his break properly and add spongy feel and tried to solve the issue that way.
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KDX4ID
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Post by KDX4ID »

So remove the circlip. Take out rod. Does this look right?

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2005 KDX220... single track sweetie
2007 KTM 450 EXC... my baby
2008 KTM Superduke... Canyon Carver
1996 Honda 650L... GONE but not forgotten
http://www.friendsoftruckeetrails.org
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scheckaet
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Post by scheckaet »

yup think so. you'll have to refill your master cylinder and maybe bleed the brakes though.
gregp
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Post by gregp »

Sorry, I didn't mean to misguide you. I do not recall my setup looking like that...
2004 Dual Sported KDX200
1999 Ninja 250 (Daughter's)
1996 DR 650 (stock, mostly street use)
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rbates9
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Post by rbates9 »

Mine dose not look like that ether.
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Post by doctord23 »

That setup with the attached rod looks like the one on my 99 KX500, but does not look like the setup on my KDX 220s.
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Post by KDXsg »

yes, just remove the circlip with a circlip piler and then you can pull out the rod. you might want to pour out the brake fuild in the master cylinder first as not to creat a mess. i suggest you change the whole internal pump with a new want and then you could run the oem or aftermarket lever. beeld the whole system with dot 4 fuild. good time also to clean everything up.
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KDX4ID
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Figured It Out (kinda)

Post by KDX4ID »

I found a lever that fits perfectly. The package says it goes to a whole bunch of late 90's KX's. Problem solved.


I also spoke with the former owner and she swears up and down that the brake lever/master cylinder were never replaced since new.

Whatever... I'm just glad I found one that fits!

Thanks to all for the help! Happy New Year!

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CURRENT FLEET
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2010 KTM 300 XCW... stop me before I buy again!
2005 KDX220... single track sweetie
2007 KTM 450 EXC... my baby
2008 KTM Superduke... Canyon Carver
1996 Honda 650L... GONE but not forgotten
http://www.friendsoftruckeetrails.org
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OLHILLBILLY
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Post by OLHILLBILLY »

That is indeed a strange set-up. Gotta be some kind of PO add on going on there.
Here's what a stock '04 master cylinder/lever looks like..
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KDX4ID
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Post by KDX4ID »

This is what I got... good, bad, or indifferent. 2003 KX500 set up.

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CURRENT FLEET
2008 KTM 990 Adventure...Alaska here I come!
2010 KTM 300 XCW... stop me before I buy again!
2005 KDX220... single track sweetie
2007 KTM 450 EXC... my baby
2008 KTM Superduke... Canyon Carver
1996 Honda 650L... GONE but not forgotten
http://www.friendsoftruckeetrails.org
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