Possible to solder a broken motorcycle brake lever?

Question in the title.

Actually the piece I want to repair isn’t a brake lever but the metal looks the same, glossy on the surface and kinda spongy on the inside.

The right repair scheme will depend on the actual metal the lever is made of. What you’re describing sounds as if it could be aluminum or pot metal.

Neither of these will give satisfactory results with normal solders, but there are special fluxes and techniques that can work. Googling gives lots of useful links.

Sounds like cast aluminum. The only high-strength repair would be welding, which is iffy on cast materials. If it’s cosmetic, you could use a metal epoxy and (if possible) some kind of backing plate or material.

Given that everything on a motorcycle is subjected to pretty good abuse from vibration and bumps, I’d be very leery of trying to repair any item that’s structural, needs full strength, retains fluids or could be a hazard if if fails while riding. If you can’t afford a new piece (or a used one), I’d check with a good welding shop to see if it can be properly repaired.

If it’s non-ferrous aluminum welding rods might work. They’re actually a form of aluminum bronze and can be used with propane or MAPP gas torches. Lead soldering won’t offer much strength. Maybe you should just use some kind of reinforcing metal and epoxy instead.

If this part is any bit of your safety equipment, please replace it. I have a 32yo KZ and parts like this are not hard to find.


More than likely it’s aluminum.

It’d be cheaper to just replace the lever than try to repair it. Also, unless it’s TIG welded it’ll probably break again. Soldering is not reccomended for this as a solder does not fuse the two parts together. You’d have broken part A, solder, broken part B. The solder could seperate at the worst time and cause an accident.

If you’re lucky, you might find someon to TIG it back together for $25 or so. However, if there are any plastic or coated or otherwise parts nearby then you run the risk of damaging them. So, all that would have to be removed.

Once again, it’ll be cheaper to replace the lever. They do sell them seperate for this reason as when you drop a bike the levers get bent and can snap.

a) Replace if possible

b) If not possible Metalset A-4

Used it on some off parts and have had them last for 30+ years

It’s a brake lever. I wouldn’t recommend a shortcut like having it welded back together. Replace it.

This. Your most important capability with any vehicle is not to go, but to stop.

What if your repair fails as you approach an intersection or left-turning car?

Spend the money, get a new one.

Guys, he said the actual piece is not a brake lever* but of similar metallic composition.
Now why he didn’t just say what the part actually is, I don’t know.

  • I read it wrong, too.