Rebuilding an 83 - 85 200X Brake Pedal and Pedal Pivot...........

[Dirtcrasher]

I may have bit off a bit more than I could chew with this one, lol........

Honda uses a teflon type coated insert (similar to whats in your forks....) in the pedal, which rides on your aluminum case. It eats up the case pivot and the backside and that cover is discontinued. The 2 "dust" seals they use, do absolutely nothing once the pedal wears which is probably after about 40 hours on a brand new OEM setup.......

SO:

A member sent me his pedal and cover, I have an NOS cover and thats what I had to work with. My 1st thought was that HIS wasn't too horrible and I ordered bushings and steel to rebuild it. I screwed up and ordered something wrong and then decided that if I'm ever gonna fix more, I have to treat them all the same in order to keep costs and my time down but NOT affect the end result.

I could have just turned the cover and made a new pedal pivot, but then you'd have steel on aluminum with nothing to wear out, but themselves. Not a good idea and just a quick fix! So I started thinking.

I wanted to use a bronze (replaceable) bushing and 2 orings to seal it. That way they could all be rebuilt again at any point..... The o-rings turned out to be so fat, that without a machine to test I was afraid the pedal would not "return". It also forced me to shorten the width or surface area of the bronze bushing too much, I didn't like it. I had it all up and running, but no test bike and I dropped that 1st plan.......

This is a picture of what I 1st did:

http://i257.photobucket.com/albums/hh220/Dirtcrasher/101_0212.jpg

NOT GOOD ENOUGH!!!!!!!!!

So, I layed in bed and it dawned on me - PLASTICS!! UHMW, Delrin and other plastics are known to wear very well. They also have self lubricating properties which makes any maintenance a non- issue (which seems to be lacking with some owners). In addition, the plastics can have a "shoulder" behind the pedal which stops that wear on the covers. I had to change steel sizes and get some UHMW to play with:

http://i257.photobucket.com/albums/hh220/Dirtcrasher/101_0246.jpg

I was MUCH HAPPIER with these results and I still have a replaceable bushing if they ever wear out. It requires the removal of the stock brake pedal pivot, mig welding a new piece of DOM tubing faced to size my 3 jaw chuck, turning down the worn cover on my face plate and turning a custom UHMW bushing on the lathe faceplate, WHEW!!. I have to use the face plate, mig welder, sandblaster and my 3 jaw chuck:

http://i257.photobucket.com/albums/hh220/Dirtcrasher/101_0173.jpg

http://i257.photobucket.com/albums/hh220/Dirtcrasher/101_0249.jpg

http://i257.photobucket.com/albums/hh220/Dirtcrasher/101_0258.jpg

And this is the end result; A nice tight brake pedal pivot for the 83-85 200X and it can be repaired in the future. I can even make spare bushings as long as I keep all the dimensions the same. With an older lather, it truly is allot of work and just getting a bit ground (I still nicked his cover) to turn that cover down/centering a jig, was hard enough..........

Here it is, DONE:

http://i257.photobucket.com/albums/hh220/Dirtcrasher/101_0269.jpg

No play but it will return. But it wasn't easy and I lost my shirt on this one....... But, we have to keep trying because as parts become discontinued (like the cover) we HAVE to fix them and why not do it well??

I'm not sure if I want to take on many of these, it's far too much labor. I'd like to be able to do them for a reasonable amount, but my labor time is up there unless now that I have a solution I can mass produce the parts to fix them..... With trikes, EVERYTHING is custom..........

I'll keep the bronze, but I still have 98 o-rings that are now useless, lol.

I'm trying guys, I really am..............................

[aldochina]

whats up DC, hope your feeling better! looks pretty awsome, love the derlin bushing idea. Deffinately looks like alot of work, especially the first time around. What a strange setup that was from honda to put the pivot on the soft case. Looks like a super quality job i'm sure they will be stoked!! Ive never seen a metal lathe in action, id love to watch you turn something on that someday. wonder how long it would take to wear out your new bushing? ive heard that stuffs wear resistance is pretty awsome!! Keep up the inovative fix it ideas man!!

[Dirtcrasher]

I'll try to keep dreamin crap up :D

Yeah, that UHMW is tough stuff. If it held up in high speed production daily then.............

Thanks for asking, felling much better now (that was a 1 day horror show)

Tomorrows lesson, Homemade ATC70 rear suspension:

http://i257.photobucket.com/albums/hh220/Dirtcrasher/101_0176.jpg

I need sleep.............

[aldochina]

cool!! I'll have to find me a spare 70 frame to tinker with. goodnight bud.

[Dirtcrasher]

I'll start a new thread on the 70 suspension.

I got the brake drum removed and I have to mig weld a .3125 (5/16ths) plate onto it that accepts all the 3 bolt front disc rotors (because I have about 10 of the dam things, :lol:

I have to fix backgear in the lathe to get a 1" hole through it, then use a boring bar to open it up some and then fine tune it. Then I just have to mig weld it in place and face it on the lathe so it runs true.

At that point, it will slide on the 70 axle and I can tighten down the axle. I'll have to fabricate a rear caliper mount on there to accept one of the 200X spare calipers I have. I have about a dozen of them..........

Then, I'll change the whole upper tube and gusset up the weaker areas and mig weld spacers through both sides of the frame to strengthen those 2 flat sides all the stock 70 frames have.

I'll need to buy a large tubing bender to make it an entire custom frame project. I can't buy one right now, so, I'll adapt TO the existing frame and strengthen it up.

I'll bet it will be 100% better,stronger and I'll have added only about 8-10lbs including the shock when it's all done...........

A custom frame may not make it any lighter, just really NEAT!! and IDK if I can weld chrome moly tubing with my Mig welder and another type of shielding gas??

It's coming out pretty cool so far.... PICS!! later today if Moms B-Day doesn't eat up my whole day.........

Back to the pedal and cover rebuild, I have enough material to do about 10. It will take 6 of them just to cover all the materials I f'd around with. Unfortunately it takes allot of ingenuity to get this stuff done and working 100% and making worth someone's hard earned dollars....

If anyone wants a brake pedal rebuilt, they ony run about 7$ (or so) to ship in the US anywhere with delivery confirmation.

The work itself I gonna try to keep at 40$ including everything and return shipping. It's a couple hours and uses ALL my machine shop services....

[Vealmonkey]

DC, I'll have to get my side cover off of my parts engine here at the house and send it up to you. I have another parts engine, but it's at blue27s house right now and I'm not sure when I'll get back up there. I also don't think the mail has been running right down here yet as I've been waiting for some parts. I haven't seen a UPS truck down my street in over a week. Snow piled everywhere. There digging it up with front end loaders and dumping it down in the inner harbor, there is so much snow. Hopefully I'll have another sidecover in my parts stash too. I would like to do 2 of them.

[Dirtcrasher]

If I can do 2 at once I can definitely take some $$ off of that quote :D

[blue27]

I have Vealmonkeys other motor and I would like to send at least one out of mine, veal and i will chat and get them out to you.

[racerxxx]

Looks nice DC. We use alot of Delrin and UHMW at my work. When we use delrin it is for mostly low abrasion stuff, then UHMW for the higher abrasion stuff cause it wears like a pigs nose, but have been experimenting with TURCITE. We have used this inplace of oilite bushings in electric clutch applications with constant turning and loads and has many hours of constant abuse with friction with great results.

http://www.aetnaplastics.com/Products/IndustrialPlastics/EngineeringPlastics/Turcite

Once again you have manufactured a great soloution for an extinct part!

[Dirtcrasher]

Thanks RacerXXX !! I'll check out that material, they have so many plastis now................

Turcite instead of a 641 oil impregnated bushing tells me it HAS to be good stuff!

[200XMichigan]

Looks really nice. Can't wait to get some spare parts (and money) to send off mine. Hoping to find an engine close by.

[NINJA]

Very nice work Steve. That looks like best way to repair those things. You should list one on eBay and see how it does.

[f22parts]

Does anyone have a good picture of this on a bike? Im trying to put mine back together and need something to look at.