Motorcycle clutch & brake levers
Kawasaki KZ 900 1976

2025-09-18, 04:52

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Andreas

*Rating: Design weakness - missing brass bushing in the bolt hole* I ordered this brake lever as a spare part for my classic motorcycle, expecting to receive a functionally equivalent component to the original. Unfortunately, the replica supplied has a significant design deviation: The *pressed-in brass bushing* present in the original part is missing from the mounting hole for the fixing bolt. Instead, the hole was simply drilled directly through the aluminum of the lever, which has several technical disadvantages: 1. *Increased wear*: Aluminum is significantly softer than brass. The direct friction between the steel bolt and the aluminum material causes the bore to be knocked out more quickly - especially under load and with repeated actuation. 2 *Clearance and inaccuracy*: Without a play-free, precisely fitting bushing, the lever can loosen or develop lateral play over time, which worsens the brake feel and is safety-relevant. 3 *Corrosion and seizure*: A brass bushing acts as a sacrificial material and reduces the risk of contact corrosion or cold welding (galling) between the pin and lever. With pure aluminum contact, there is a higher risk in the long term. 4 *Limited maintainability*: While a worn brass bushing can be easily replaced in the original, the entire lever would have to be replaced in the replica - economically and ecologically disadvantageous. Overall, the component appears functionally suitable at first glance, but is *constructively inferior* compared to the OEM part due to this omission. For safety-relevant components such as a brake lever, this compromise is *not acceptable* in my view. *Conclusion:* If you value durability, precision and safety, you should choose a part with a corresponding bushing or retrofit a bushing yourself - if technically possible.

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