Replica foot brake lever shaft with oversize

The brake lever shaft item 10122RP is our solution to a well-known problem on the XT500:

The foot brake lever wobbles and has play because both the shaft and the seat in the frame are worn out.

Our item 10122RP is a reproduction of the original foot brake lever shaft in a high-quality, tolerance-reduced design made of stainless steel. The shaft diameter has an oversize of 18mm.before installation, the worn seat in the XT frame must be adjusted to the new dimensions. 

The installation steps:

- To prepare for the repair, we recommend removing the swingarm. This makes it easier to reach the shaft seat in the frame, although this is not absolutely necessary. In the instruction video, we show the repair without removing the swingarm.

- Drilling and manual reaming of the shaft seat in the frame to exactly 18.00 mm 

- A cordless drill driver with adjustable torque and holder for 10 mm drill bits is required - this is the usual standard for Bosch, Makita & Co.

- After removing the old shaft and cleaning the shaft seat, it is drilled out with the 17.5 mm drill bit, ensuring that the drill bit is guided parallel, the speed is low and the shaft is cleaned and re-oiled frequently during the drilling process.

- The shaft seat in the frame is then reamed to 18 mm using the reamer. The reamer is supplied with the appropriate tap wrench, no additional tools are required. This should also be well oiled and cleaned. With the swingarm removed, it is possible to ream the fit from both sides.

- Replace the worn-out brake lever shaft with our oversize shaft item 10122RP - all attachments (seals, foot brake lever, brake linkage) can be retained unchanged. Well greased, the new shaft now fits into the repaired shaft seat without play. Matching seals are item 10075 and are required twice.

The difference is impressive.