FZ-09 Aftermarket Brake and Clutch Lever Insert

thingiverse

I recently purchased a bike and discovered that one of its previous owners had swapped out the stock levers for $22 Ali Express alternatives. I'm not a fan of cheap aftermarket parts, so this development didn't sit well with me. The new levers seemed okay at first, but they arrived partially assembled - the adjustable extension was detached, leaving only 2-finger shorty levers. The levers feature a dovetailed extension held in place by a single hex bolt. Unfortunately, the bolt strikes the grey material first, rather than the red material, which means that even with a washer it doesn't properly bite into the red lever extension. I headed to ACE and picked up some new bolts and washers, but ultimately decided to take a different approach - 3D printing. That's when my love for 3D printing really shines through. The PETG inserts fit snugly into the recessed area of the levers, while the bolt hole aligns perfectly with the threaded hole in the grey part. There's minimal force exerted horizontally, and the dovetail bears most or all of the pulling force. Now it's just a matter of waiting to see how they hold up over time.