As I searched the forums, looking for answers to my sloppy rear brake pedal and I saw a lot of frustration and fabrication going on with the GG rear brake pedal. It seems like a lot of people fight sloppy pedals and dont like the slotted clevis pin. There are some good threads talking about modifying YX or KX pedals and a host of aftermarket, expensive clevises. I have stumbled on an insanely easy fix:
1. For the pedal slop, replace the stock brake pedal pivot bushing with the one from Checkpoint Offroad (http://checkpointoff-road.com/store.html) part number 5007, $23 bucks, arrived in 3 days. Besides being 303 stainless, the flange on the bushing is about 3mm compared to the stock 1mm. This translates into shifting the pedal out away from the case, which for me was huge! I used a stainless washer on the outside that fit perfectly over the bushing and allowed the pedal to snug up nicely. Upon torqueing the pedal pivot nut, there was ZERO slop. Just perfect linear travel. AWESOME!
2. Now the really good part. I hated the slotted clevis, and I know there must be a reason for this design, but I just dont like the feel. My 2002 KDX220 sitting right beside my EC has no slot in the clevis, and looked to be a perfect fit. The clevis was $40+ from the web, and the best I could find on e-bay was around $40 for the whole assembly. I also looked into all the trick aluminum clevises from Zeta, Fasst, Ride, Hammerhead, etc. Of course none for GG and again some comments on the forums about buying them and modifying them for fit. Frustrating. Now the epiphany! I was talking to my maintenance supervisor at work, and showed him the pedal, looking for ideas to take the slop out of the stock clevis. We were ready to weld washers on each side, when he asked me what size the brake rod was that goes into the clevis. Why M8 I told him. He smiled headed to the parts crib and came back with this little piece of heaven. It is Festo Part Number 3111, SGM8 Rod Clevis (http://www.festo.com/pnf/en-us_us/p...ch&Mode=portal&lang=en-us&country=US&key=3111 ). We use it on hundreds of powerful, very high duty cycle (6000 strokes a day) Festo air cylinders in our assembly plant, AND IT COST $4!!! I saw one on e-bay sell for $2!!!. The damn thing threaded right on my brake rod, tightened up the jam nut, and viola, NO MORE SLOP. Super firm pedal, great transfer of power, and one very happy GG owner!!! It also comes with a pretty trick snap on clevis pin. I might replace this with a cotter pin type, but for now it looks and feels great! The part is available in galvanized steel or stainless (PN 13568). I have the galvanized one, so I will report back this summer on the durability. I am confident it will rock!
Attached are pics of the two clevises side by side, and the set up on my bike. I see several people have gone away from the frame mount return spring to the master cylinder rod mounted return spring kits. I will add this next, but for now the frame to pedal spring is working fine.
Hope this helps, let me know if you need more pics or info!
Happy Trails! Mike
1. For the pedal slop, replace the stock brake pedal pivot bushing with the one from Checkpoint Offroad (http://checkpointoff-road.com/store.html) part number 5007, $23 bucks, arrived in 3 days. Besides being 303 stainless, the flange on the bushing is about 3mm compared to the stock 1mm. This translates into shifting the pedal out away from the case, which for me was huge! I used a stainless washer on the outside that fit perfectly over the bushing and allowed the pedal to snug up nicely. Upon torqueing the pedal pivot nut, there was ZERO slop. Just perfect linear travel. AWESOME!
2. Now the really good part. I hated the slotted clevis, and I know there must be a reason for this design, but I just dont like the feel. My 2002 KDX220 sitting right beside my EC has no slot in the clevis, and looked to be a perfect fit. The clevis was $40+ from the web, and the best I could find on e-bay was around $40 for the whole assembly. I also looked into all the trick aluminum clevises from Zeta, Fasst, Ride, Hammerhead, etc. Of course none for GG and again some comments on the forums about buying them and modifying them for fit. Frustrating. Now the epiphany! I was talking to my maintenance supervisor at work, and showed him the pedal, looking for ideas to take the slop out of the stock clevis. We were ready to weld washers on each side, when he asked me what size the brake rod was that goes into the clevis. Why M8 I told him. He smiled headed to the parts crib and came back with this little piece of heaven. It is Festo Part Number 3111, SGM8 Rod Clevis (http://www.festo.com/pnf/en-us_us/p...ch&Mode=portal&lang=en-us&country=US&key=3111 ). We use it on hundreds of powerful, very high duty cycle (6000 strokes a day) Festo air cylinders in our assembly plant, AND IT COST $4!!! I saw one on e-bay sell for $2!!!. The damn thing threaded right on my brake rod, tightened up the jam nut, and viola, NO MORE SLOP. Super firm pedal, great transfer of power, and one very happy GG owner!!! It also comes with a pretty trick snap on clevis pin. I might replace this with a cotter pin type, but for now it looks and feels great! The part is available in galvanized steel or stainless (PN 13568). I have the galvanized one, so I will report back this summer on the durability. I am confident it will rock!
Attached are pics of the two clevises side by side, and the set up on my bike. I see several people have gone away from the frame mount return spring to the master cylinder rod mounted return spring kits. I will add this next, but for now the frame to pedal spring is working fine.
Hope this helps, let me know if you need more pics or info!
Happy Trails! Mike
