In my last blog, I told the story of the rear brake pedal and how I managed to bend it in half after getting it stuck in the side of a rut on Salisbury Plain.
First I bent the pedal back to its original position as far as possible and then attempted to straighten it a bit more to tuck into the side of the bike by the simple expedient of clamping it in a bench vice, heating it up with a blow torch then getting a very large ring spanner over the lever and bending it as required. I also replaced the (very bent) original foot plate with one from a KTM EXC that is only half as big, this was a bit better but not perfect.
Next step was to find an alternative pedal that doesn’t stick out so far, I took a close look at the 790/890 pedal and it certainly looked like it might fit. Although the obvious issue was it mounts inside the frame, whereas the 390 pedal fits to the outside, so maybe it was just an optical illusion that it doesn't bend as far? The only way to find out was to get hold of one and try.
The downside is that a replacement 390 pedal is bad enough at £55 but a 790 is £79!!!
But then a few problems First problem is the part where the brake rod attaches is thicker on the 790 pedal.
This is because instead of a forked rod with a clevis pin that the 390 uses, the 790 has a rose joint that bolts to the side of the pedal.
I considered stealing the rod from my 525EXC as it’s the same type as the 790 but realised it was quite different where it goes into the master cylinder. So instead I spent a few minutes with a file and reduced the width to match...
Then I tried to push the clevis pin through the hole and discovered it is both smaller and lacks the steel bush the 390 pedal has:
Another problem can be seen in the photo above, the hole for the return spring runs back to front, whereas on the original pedal it's from side to side. Not really an issue as I drilled another hole with a 2mm bit in the correct orientation.
Next issue was the thickness off the lever at the pivot, if you look at the 390 lever the bearing just pushes in from either side. But on the 790 it can only go in from the inside as it sits against a shoulder on the outside…