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Well in a recent crash I broke the original brake pedal on my '90 EX. I ordered a replacement and upon installing it a part bent. It is the hook where you attach the spring. I figured maby it got dropped and was damaged so I took it back and got another one. SAME THING. I couldn't believe it. Same bend, same place, same reason. I wondered why my old pedal didn't do it. Here's why:

http://img380.imageshack.us/img380/997/1001328nz6.jpg
http://img382.imageshack.us/img382/8756/1001329ja4.jpg

New pedal is on the right, old on the left.
As you can see, the old one has that spring arm welded in place, not for show, but to prevent this EXACT problem.
And cannot fathom why they removed that crucial weld. It pure idiocy.


I already paid around $80 bucks for this pedal, so I don't feel I should pay any more for repairs or a custom job.
I was thinking about taking it to my local Kawasaki Dealer, what do you guys think I should do?
 
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I got it from Bert's Mega Mall, they already sent one back. I don't feel there's anything that they can do either than ask Kawasaki for another one.
If I do get the money back what am I supposed to do then? The old pedal is really jacked up, and is much harder to bend back then the new one. And the replacement has to cost exactly the same as my refund.

I don't know anyone with any welding tools. I was hoping the Kawasaki dealer had them and would be willing to weld it for me.
 
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Nah, I live here is sunny California. It's ironic , TV portrays Cali as being the hotspot for chopper customs and the lot, but it's really hard to find a place that actually does that. They are few and far between.

As far as BikeBandit goes, I'll probably end up getting it off of ronayers as their parts are even lower in price. If the same problem is there again, I'll give in and purchase a welder. Home Depot has a few cheapies. It just makes me so angry that a manufacturer would skimp on quality like that. If I hadn't been paying attention and put that thing on there, it could have meant my life.
 
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I guess i'll hit the yellow pages tomorrow. I'm still going down to the dealership/service center, after all thats where they're ordering it from, and give them what for. They might help, might not, worth a try.

Thanks for all the help!

--Kyle
 

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Any place that does repair work ought to have a guy on hand that can weld - well, they should, but whether they do or not is anyone's guess.

Just looking at that part, I can't believe there isn't a weld where it needs it. Any chance Bart's could look through their parts to see if they just got a batch of defects? They should have a contact number for the manufacturer that would clear things up quickly.
 

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That's a factory Defect and should be returned for full credit or replacement at no charge. Those things are welded by a robot and are all the same, this one was done as the mig wire ran out and should never escaped the factory.

FOG
 
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FOG said:
That's a factory Defect and should be returned for full credit or replacement at no charge. Those things are welded by a robot and are all the same, this one was done as the mig wire ran out and should never escaped the factory.

FOG
They've already replace it before for no charge. The old one had the same defect. And that was about a couple weeks ago.
 
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OK I just got back, they said that it was definitely a defective part. They had the local distributor find all the ones in the warehouse to see if they too have the same problem. If they do, it could be months before I see a replacement. :'( :'( :'(
 
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Yea welding is that what I'll have to do.

The distributor told the dealer that there was no defect, that is how they are made. They basically blamed me for not putting it on right. No refund will be issued and no further trade-ins will be accepted. :'(

Now I just have to find someone nice to weld it, anyone is SoCal? ;D
 

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GMR_RUNNER said:
Yea welding is that what I'll have to do.

The distributor told the dealer that there was no defect, that is how they are made. They basically blamed me for not putting it on right. No refund will be issued and no further trade-ins will be accepted. :'(

Now I just have to find someone nice to weld it, anyone is SoCal? ;D
I'd tell them they need to quit selling defective parts regardless of what the mfg says. If you brake and the part bends then somebody is going to get hurt. Luckily you found out now.

If you can't find a good welder, hit a local exhaust shop. They'd probably throw a bead on there for a few bucks, and those guys have to be pretty good with heat control (so they don't just melt away the metal).

EDIT: Have you shown them the original piece? OEM may not mean Kawasaki, but it means original spec or equivalent. The picture you have above proves it is not up to OEM spec. Personally, I'd return the P.O.S. they sold you, tell them that you're not endangering your life for their $60 or whatever it was, and have the welder add a piece to your old part. Customers are > money, but that OEM producer doesn't think so.
 

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Also, does anyone in this discussion have a '93 model (just before the brake swap)? I'd be interested to see if Kaw changed this piece at any point between '90 and '93.
 

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If they told you it is not a defect they are lying to you. Plain and simple. It is obvious that the welding machine put an arc to that area but there was no filler wire. You can see the results of the arc on the round.
Just get it welded and be done with it. Don't forget to re-paint it after you get it welded.
 
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