Brake Lever Bent - How to Straighten

  • TomasDouglas
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Brake Lever Bent - How to Straighten

22 Sep 2015 18:58
#691464
I have a 1980 KZ550A that I am putting back together. The front brake lever appears to be bent see picture. I would appreciate any help or suggestions on the best way to try and straighten the brake lever out without cracking or breaking it.
Thanks
Tomas Douglas

Attachment IMG_0097.jpg not found

Tomas Douglas
1980 KZ 550A
1986 GPZ 550

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  • martin_csr
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Re: Brake Lever Bent - How to Straighten

22 Sep 2015 19:13 - 22 Sep 2015 19:13
#691465
Replacements are pretty cheap. I'd be worried about the thing snapping during a panic stop,
but metallurgy isn't my strong suit. :blush:
Last edit: 22 Sep 2015 19:13 by martin_csr.
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  • jackleberry
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Re: Brake Lever Bent - How to Straighten

22 Sep 2015 20:21
#691468
You can get a new one for like $10. That's cheap insurance.
1997 KZ1000P (P16)
2001 KZ1000P (P20)

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  • davido
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Re: Brake Lever Bent - How to Straighten

22 Sep 2015 21:16
#691472
You can bend it back with heat but as Martincsr says itll weaken it. Not a good idea.Buy a replacement.
www.kzrider.com/forum/11-projects/594313-csr1000-project-build
CB550 (1978)
CB500/4 (1972)*
KZ1000CSR (1981)
XT 600E (1999)
TDM900 (2003)
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  • punisher11b
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Re: Brake Lever Bent - How to Straighten

23 Sep 2015 02:54
#691477
Actually if you keep it below the annealing temp of the metal you won't make it too soft. if you heat it up say to about 300-400f you will prevent most dislocations in the metal ( it won't become brittle) . heating softens, cold working/ bending hardens. One undoes the other quite a lot. It's all about doing it so it's not to easy to bend but not too hard. so I would grab a torch, a vise and bend as close to kink as possible to prevent new unwanted bends.
(then again you can pick one up for cheap, just thought I would chip some engineering thoughts on bending metal) :P
- good luck

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  • 531blackbanshee
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Re: Brake Lever Bent - How to Straighten

23 Sep 2015 03:52 - 23 Sep 2015 03:53
#691487
i have heated and bent em back before with good luck.
although i used a press and heat.a vise with soft jaws will work pretty good.
z1r's have model specific front brake levers and are hard to come by so i do what i can to save em.
i have paid $80.00 for a lever from japan.
it hangs on the wall,
i run a brake and clutch lever that i straightened.

leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
Last edit: 23 Sep 2015 03:53 by 531blackbanshee.
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  • TomasDouglas
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Re: Brake Lever Bent - How to Straighten

23 Sep 2015 20:16 - 23 Sep 2015 20:19
#691660
Thanks to all for replying. I was hoping I could maybe salvage the lever, as I already have about $2800 CDN in parts that I have put into this bike. Most parts have to come from the USA and with exchange, import duties, and extra shipping costs everything adds up. I am getting to the final stretch and I appreciate the comment as I never thought about it snapping under pressure.
I will try a fix just for the practice and look for a replacement on ebay.
Thanks Tomas
Tomas Douglas
1980 KZ 550A
1986 GPZ 550
Last edit: 23 Sep 2015 20:19 by TomasDouglas. Reason: Add due to finding a cheap lever.

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  • TomasDouglas
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Re: Brake Lever Bent - How to Straighten

06 Nov 2015 14:51
#697527
This is a final follow up on the problem. I ordered a replacement lever and it came to $9.99 plus $12.95 shipping. However it is no where near the quality of the original even the hole for the bolt was undersized and I had to drill it out. Eventually I may try to straighten the original or try to buy an original.

Attachment IMG_00604.jpg not found

Tomas Douglas
1980 KZ 550A
1986 GPZ 550

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  • pete greek1
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Re: Brake Lever Bent - How to Straighten

08 Nov 2015 07:50
#697740
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TomasDouglas wrote: This is a final follow up on the problem. I ordered a replacement lever and it came to $9.99 plus $12.95 shipping. However it is no where near the quality of the original even the hole for the bolt was undersized and I had to drill it out. Eventually I may try to straighten the original or try to buy an original.

Attachment IMG_00604.jpg not found


Here's a new, NOS lever

Pete
1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!

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  • dom2570
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Re: Re:Brake Lever Bent - How to Straighten

08 Nov 2015 11:14
#697766
I hit mine with a rubber mallet till it was straightened out. I'm not going to claim it was the smartest thing to do, but it has been working fine for several years now.
Whip it like a mule!

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