Brake pedal and gear pedal linkage excessive wear

[Humbug]

Background:
Bros RC31 J 1988 with extremely high mileage
No garage, but am able to take basic stuff apart, and sometimes put it back together.
Bike kept a long way from keyboard

Issues:
-Excessive wear on the gear change linkage (to the extent that the rose joint can be popped off)
-Excessive wear on the brake pedal (moves side to side as you look down on it)

From reading the forum, looking at WeMoto, David Silver etc, I have gathered that neither are available new. There are some rusty looking items that pop up on ebay for not terribly much money. Chances are they are better than mine, but it might be money down the drain.

I want to keep the bike stock; I find the position comfortable.

Thoughts most welcome. What I'd like to identify is where the wear is, and if replacing components (seals, circlips,etc) would make much difference:

http://hawkworks.net/hawkfiche/pedal.html

Happy to buy anyone's standard kit if they can show it's got little wear; I'm in the UK.

[6]

Curious what "extremely high mileage" is?

There is a lot of info on here as to what lower controls fit from other bikes. Personally i have never seen wear that bad, but i also don't use shift linkage or the stock shift lever most of the time. Others might have experienced that.

How much side to side play are we talking about in the rear brake lever?

[Talon]

Make sure you have the seals, and more importantly, the washer inside the circlip. Without that washer the pedal can move in and out.

As for the shift pedal, like 6 said, there are a bunch of different options.

[Humbug]

The kilometrage? Nearly 190,000.

and by side to side movement, it’s not so much in and out, it’s that I can twist the brake pedal by maybe 30 degrees left to right, as you look down on it.

[DrPMC]

Have you seen these:

https://www.ebay.co.uk/itm/312927626051?fits=UKM_StreetName%3ABros&hash=item48dbf0a343%3Ag%3ALvQAAOSwgXRgZZaP&LH_ItemCondition=4

https://www.ebay.co.uk/itm/154156816140?fits=UKM_StreetName%3ABros&hash=item23e476570c:g:aq0AAOSw4dNfktZC

The brake pedal on offer looks especially good.

Alternatively, if you have access to some basic facilities to drill and tap steel it wouldn't be too difficult to replace the rose joints and the linkage on the gear lever with new stainless parts, which are very reasonably priced these days. I'd imagine that the lever pivot holes could be bushed but that's a bit more complicated I suppose.

[Humbug]

Daft question - but I don't have a micrometer; is the gear linkage (14, bolt, tie rod, 90065-ML0-900) M5 or M6?

[squirrelman]

should be standard yearly maintenance but nobody does it: referring to the parts diagram, pull off the bolt #16 and remove sleeve #6 for cleaning and grease.

[DrPMC]

Daft question - but I don't have a micrometer; is the gear linkage (14, bolt, tie rod, 90065-ML0-900) M5 or M6?

I recall that they are all M6. I believe that one end of the rod has a left hand thread.

[Humbug]

I recall that they are all M6. I believe that one end of the rod has a left hand thread.

You guys are the absolute best, thank you.

I'm going to order one of these:

https://www.askthemechanic.co.uk/shop/m6-threaded-rod/119-m6-threaded-stud-rod-left-handright-hand-thread-120mm-0744881753715.html

The length is 120mm, which is close enough to what mine is, at 123mm.

Long post follows, based on what I originally posted on FB.

[Humbug]

OK, so I've been down the rabbit hole of 33 year old Grey Import parts availability. Trying to buy new is a bit hard.
Why buy new? My bike, despite it's fairly disgusting appearance, is mostly stock looking.

Gear linkage side

On the drawing, gear pedal 3 is f***ed. I definitely need a new one as there's a lot of play with both pieces I have, and on the one in the house, the rose joint pops off.
I've found a new one! Fingers crossed it arrives.

Gear linkage 14 is not available anywhere.
I have two bent ones from crashes.
I was wondering whether to clean it up and take to my mechanic to see if it can be straightened, but will just order the rod linked above.

The part with the spline (to the left of no. 18, goes into the gearbox) is available new from David Silver, but possibly is OK,
though there's a lot of play again in the rose joint on both of mine. I have ordered a new one, and will compare to the old one I've taken off and cleaned up.

Collar 6 is NLA and wobbly. I make need it built up, or it may fit snug if I get a new pedal. I've asked DS if they can source one.

Other parts on order from DS:

4 x 2 24706-MK3-770
15 x 2 90101-ML0-720
7 24781-KR3-770

Brake side

I've been out to my bike and partly disassembled it to take a look. Brake lever 11 is really wobbly. I don't know if it's the housing or the back of the brake hanger, but have taken a gamble and also ordered possibly the last new one available. Whether it turns up is another question. I have ordered the washers and miscelaneous gubbins from DS:

13 53312-657-000
19 x 2 91251-444-000
21 94511-15000

The lack of new parts isn't really surprising I guess, but we will need to think up creative solutions in the future.

I now need to order the following tools; I guess not the cheapest I can find on ebay?:
-circlip pliers
-micrometer

Humbug

[Humbug]

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[Humbug]

240912892_10159302970123672_1605451315949294175_n.jpg

[DrPMC]

Regarding the micrometer, I’ve tended to find that I use a vernier all the time and a micrometer rarely. I have a couple of mityotoyo verniers, a digital one and an old school one which I’ve been using for decades. The ones you can get for a tenner from Lidl sometimes are quite usable. Be careful with the eBay ones - the cheap ones are often made of a soft zinc alloy.

It may not what you are after but one solution to having an old bike with poor spares availability is to buy a mini lathe, then you can make all the bushes and other small bits you need to replace or repair worn parts. With a small milling machine you can make almost anything.

Regarding finding spares, I expect you’ve just tried googling the part number? Sometimes it will be used on other Hondas or be available somewhere in the world.

With the gear charge rod and rod end bearings, you can replace that with a bit of 6mm stainless, threaded m6 (right hand thread not essential) and get a couple of Chinese stainless rod end bearings and drill and tap the brake arm and lever to suit. Much better than soldiering on with worn out rusty stuff.

[Humbug]

Regarding the micrometer, I’ve tended to find that I use a vernier all the time and a micrometer rarely. I have a couple of mityotoyo verniers, a digital one and an old school one which I’ve been using for decades. The ones you can get for a tenner from Lidl sometimes are quite usable. Be careful with the eBay ones - the cheap ones are often made of a soft zinc alloy.

Thanks for the info.

It may not what you are after but one solution to having an old bike with poor spares availability is to buy a mini lathe, then you can make all the bushes and other small bits you need to replace or repair worn parts. With a small milling machine you can make almost anything.

I'm so envious of anyone with this getup. At the moment, I'm living in a flat without even a garage. Hopefully my circumstances will change in the next few months, and a lathe is pretty high on my list of requirements; no idea how to use one though..!

Regarding finding spares, I expect you’ve just tried googling the part number? Sometimes it will be used on other Hondas or be available somewhere in the world.

Yes, and the parts I'm left over are the hard parts.

With the gear charge rod and rod end bearings, you can replace that with a bit of 6mm stainless, threaded m6 (right hand thread not essential) and get a couple of Chinese stainless rod end bearings and drill and tap the brake arm and lever to suit. Much better than soldiering on with worn out rusty stuff.

Right, this is where things get interesting.

The gear rods I can find from this company:

https://www.askthemechanic.co.uk/shop/m6-threaded-rod/119-m6-threaded-stud-rod-left-handright-hand-thread-120mm-0744881753715.html

And the rod ends:

https://www.hendersonbearings.co.uk/sphs6ec-6mm-female-rod-end-bearings-m6-right-hand-stainless-steel-ptfe-rvh.html

https://www.hendersonbearings.co.uk/sphs6ecl-6mm-female-rod-end-bearings-m6-left-hand-stainless-steel-ptfe-rvh.html

After talking to my mechanic, he can drill out the gear levers, what I'm left with are the fasteners to go through the gear levers and then through the rod ends. Any idea, please?

[DrPMC]

I got my lathe when I was living in a crappy flat. It was secondhand from eBay and I learned how to use as I went along.

On my Bros, the rose joint is fixed to the gear change lever with an m6 stainless button head socket head screw.