FZRSupport: the FZROnline Archive

Finally, got the brake lever off yesterday. I tried a while back but the retaining bolt's head was badly chewed and I couldn't get an allen key to gain a purchase. Resorted to mole grips on the head of the bolt and the thread that was exposed underneath of the brake lever body but still no go. Soaked it liberally with penetrating fluid and decided to let it do it's stuff for a few weeks.

Yesterday still seized solid so I cut the exposed and chewed threads of the retaining bolt (didn't want them to tear the thread in the brake lever housing on the way out). Several careful blows with a hammer on the bolt head and finally I was able to tease it out with an allen key.

My problem now is getting the bush out of the brake lever, it's stuck fast. I have applied gentle heat and then tried to drift it out but it wont budge. I think the bush is brass so would drilling it out be a better approach?

your probably looking at a new one. when you get corrosion like that you usually end up breaking something trying to remove the bushing. i have a brand new handle but shipping would be alot.
wish you luck

Thanks Cowboi,

The lever is cheap enough £10.00 with postage (about $15) but I am trying to save the pennies for a chain/sprocket set and new brake hoses. Plus I am going to need a new bush now! It seems that it is all the little incidental parts like this that slowly add to the cost of a project.

Good news is I got it out. I let it soak in penetrant overnight and decided it was kill or cure. Managed to beat it out without ruining the lever. Used a dremel to polish the lever up and all looks good to go.

The offending bush (probably not been lubed since it was first put on)



The rescued lever