Fixing Aprilia Falco rear brake lever knob
Recently my bike was laid over on its side at speed (read: "I crashed my bike"). One of the pieces that broke was the little knob that sticks out of the rear brake lever. It basically allows me to press down on the brake lever. Rather important, especially when you also broke the front brake lever.
Anyhow, you can't buy the knob new and the whole assembly cost about $150. No thanks.
I had combed the crash site for any pieces that might have scrapped off. Finding the brake knob I pocketed it... That was the least of my worries at the moment.
I measured the threads on what was left of the bolt and found a bolt with similar properties. The bolt I ordered had measurements of 10mm Diameter shoulder screw, 8mm 1.25 pitch thread, 36mm long. I hacked off the end of the bolt and salvaged the rubber.
Next came the fun part. Using a combination of fire, a drill press, tap, determination... And someone to do it for me as I watched, the broke off bolt was finally removed from the lever and the threads were cleaned up.
We have an ultrasonic cleaner here at work, so I threw the parts in there and they came out very shiny!
Lastly I threw some grease in the areas that rubbed and bolted it back on. All told about 1.5hrs of tinkering during my breaks at work and I have a very pretty new brake lever!
