Brake Pedal Assembly

Voyager brake pedal — Photo 2 – Pedal side view of Kawasaki brake assembly

The rear brake pedal assembly from the Kawasaki Voyager donor will be used on the new trike. (Photos 1 and 2)

Mounting plate for brake pedal — Photo 3 – 3 x 1/4″ flat stock is used to make a mounting plate. Bolt holes are drilled to match the brake pedal assembly.

Quarter inch flat stock is used to create a mounting plate for the brake pedal assembly. (Photo 3)

Mountin plate bolted to brake pedal assembly — Photo 4 – The fabricated mounting plate is bolted to the brake pedal assembly.

The mounting plate bolted to the brake pedal assembly (Photo 4)

Photo 5 – A wedge is cut from 1/4″ flat stock to offset the brake pedal assembly and allow the pedal arm to clear the frame.

Since the lower frame rail of the trike runs at an angle, the brake pedal bracket must be offset so that the brake pedal arm will clear the frame. A wedge shaped spacer is cut from 1/4″ flat stock to set the brake pedal assembly at the correct angle. (Photo 5)

Angled spacer welded to brake mounting plate — Photo 6 – The wedge (arrow) is welded to the mounting plate.

The wedge shaped spacer is welded to the mounting plate. (See red arrow in Photo 6)

Brake pedal bracket clamped for welding to frame — Photo 7 – The pedal assembly is positioned for welding to the frame.

Finished brake pedal bracket — Photo 8 – Brake pedal mounting plate welded to the frame.

The entire brake pedal assembly and mounting plate are positioned on the frame to place the pedal where you want it and the assembly is clamped in place for welding. (Photo 7)

The final mounting position of the mounting plate is too close to the frame to remove the attachment bolts. So the bolts are permanently welded to the mounting plate. Photo 8 shows the completed mounting plate welded to the frame with the pedal assembly removed.