RGS post/stub for rear brake lever return spring broken

henrywillms

henrywillms

Hero member
Location
Canada
On my RGS the post/stub that the return spring for the rear brake lever wraps around is broken off flush with the adjoining web. So the spring is not grabbing anything.  Does anyone know the size (length) of this cast stub, either measured from the inside of the flat casting or from the web. Does it have a groove in it for the spring?  Am I best to get a good welder to weld an extension on to remaining stub, or would it be ok to drill and tap a stud into the remaining post.  Thanks. 
 
G'day Henry,
Just so happens I have the plates off while I do a chain/sprocket conversion and other 'whilst I'm at it' jobs.
The post measures 15 mm in length from the web and is approx 9 mm in diameter. There isn't a groove as the brake actuating arm keeps it in place. The post not only acts as a spring retainer but also as a stop for the whole brake lever assembly, stops it swinging down and dragging on the deck.
As the post takes quite a load, I would be tempted to fit a countersunk bolt and nut through the plate. If nothing else, it would give the rivet counters something to ruminate over.

Terry
 
Further to the above, the post stops the piston in the master cylinder being permanently 'loaded'.
 
Hi Henry

do your plates have the hole at the back end of them for the supporting rod for the Exec saddlebags?

I know I have ONE spare Exec plate tucked away ins torage, and I am pretty sure it is from the brake side, I think..... if it is from the brake side, are you interested, or would you rather fix what you have?

Paul LeClair
 
...same thing happened on my bike.

Originally I was going to drill and tap a short bolt through where the stub broke off. Instead I just drilled through the whole plate and did what Terry suggested. Worked fine and didn't look too bad at all.

eventually I just secured a new footrest plate and have managed not to brake the stub off this one yet.

good luck with it. It's a prick the get it all back together with the spring... need 3 hands.
 
Paul, I do have the holes drilled through for the Exec Bags, I drilled them. Let me know what you find at the Leclair Laverda Parts Emporium.

Thanks for the advice on the fix guys, I'll look at the stud method. Interesting that it happened to others, not a problem I would expect to happen.     
 
Today I had a buddy with a milling machine and lathe help me get most of the way fixing the broken stub. First we put the whole footrest casting into the milling machine and put a flat surface (parallel to the the plate) on the broken stub. It ended up being just below the adjoining webs. The drilled a hole in the existing stub, depth to about the surface of the plate, diameter was 3/8". Then using some 6061 aluminum he made a new stub. It has 3/8 diameter to fit  in the the hole and then going to 9mm diameter for the actual extension of the stub to replace what broke off. It is a length of 15mm long from the web outward. But a chamfer on the stub where it buts up to the casting to allow for better welding. Oh yea on the small diameter part that goes into the casting, he put a very small groove to allow air out when tapping the new stub in. It was interference fit, a slight tapping with a hammer got it in place. Next off to an experienced welder to weld it up. I think this should hold. It is not really a precision piece and in theory not under much stress but they do seem to break. Mine broke after my brake locked up on the highway and I grabbed the brake pedal to try and release it.  Sorry I did not take pictures but I hope this helps if you want to use this approach. I felt this was the strongest was without drilling right through the outside of the casting to put a bolt through.
 
This is how I fixed the same problem it has worked fine I did not drill all the way through so it looks original from the other side. Rebushed while I was at it so no slop in shaft.

Will
 

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