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Old 04-06-2013, 04:30 AM   #1
Radio1 OP
Joined: Feb 2013
Oddometer: 38
Rear Brake Lever Push Rod

I was on a trail last weekend and part of the rear brake assembly fell off, I must admit I was thinking for about 20 minutes Hmmmm... rear brake lever feels a bit slack..... all of a sudden no rear brake.

When I inspected I found the pushrod that goes up into the master cylinder was gone along with the little rubber boot that goes over it.

When I called my local KTM, i was told no parts in Australia - 4 - 6 weeks from Austria. I then got in contact with an American supplier $45.00 and about a week ( it's a $17.00 part + express post )

Under further investigation I decided I may be able to fabricate somthing myself, I am now wondering if what I have done is ok, at least until the genuine part arrives,

To get the rubber boot I need to buy a whole new piston which is $50.00, perhaps I can locate a boot that will work elsewhere.

Radio1 screwed with this post 04-06-2013 at 04:38 AM
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Old 04-06-2013, 04:41 AM   #2
Joined: Mar 2011
Location: Northern Illinois
Oddometer: 9
Make your own boot from a scrap of flexible leather. Stitch into a cone shape with the suede side out, pull it smooth side out, fasten to the master cyl. and rod with zip ties. Voila!
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Old 04-06-2013, 04:50 AM   #3
On a "Quest"
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Joined: Apr 2007
Location: West Des Moines, IA
Oddometer: 3,281
Nice fab work there! Anything that would keep dirt out should work

I would check any available motorcycle shop. I bet you could source something that you could zip-tie in place.
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Old 04-06-2013, 06:46 AM   #4
Bad knees
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Joined: Feb 2008
Location: S.F. Bay Area
Oddometer: 743
Any automotive parts & accessories store should have something. Maybe a hobby store that sells RC watercraft - pick up a control rod boot:

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