Hi there, I had a friend who dropped my in the driveway. I went to try to ride away and my rear brake no longer worked. So i started to rip the side off and realized the control plate has snapped. So i got to the point where I have a replacement piece (Part Number 2084015) but im struggling trying to get it all back together. If anyone knows of a tutorial or a step by step somewhere. Please let me know!
I unfortunately havent gotten anything done with this yet. i've been focusing on other projects. If anyone can chime back and assist that would be great.
The part comes in later this week so I’m going to take a stab at it this weekend. I’ll take pictures along the way and let you know
Removal It sucks to do but it can be done. The part number for my ‘22 T100 was T2084015 ($95 USD) and was etched on the back of the control plate. If you want to change brake fluid, brake levers, or foot pegs, this a great time do it since you have to tear into everything pretty good to unbolt it all from the broken control plate. I started by removing the plastic brake light switch bracket and undoing the connection. It is one hex head bolt and then slides down and out. Finessing the wire and connector around your master cylinder is a little difficult to do but doable for removal. After that, I took out the 2 bolts holding the plastic chain guard to the control plate. It also took a little finesse but came out by pulling up and out to the right. After that, everything is pretty cleaned out and you should be able to access the 2 bolts that connect the master cylinder to the control plate (I used a pipe wrench to sort of grip the broken control plate to give me some leverage as the bolts are tight). Then take out the 2 bolts that go from your broken control plate to the frame of the bike. One of those also goes through the foot peg and brake pedal bracket. After removing everything, you should just be left with the master cylinder and brake lines dangling with the brake pedal still attached. From the broken control plate, you’ll need to remove the brake pedal mount and the slider that goes inside of the brake pedal switch. As I was pulling all of the bolts and parts off, I made sure to place them in separate labeled plastic bags to not get anything confused. I also did some cleaning around the sprocket due to dirt and chain lube remnants. Installation of the new plate It all went back together fairly easily (better than taking it apart). I started by attaching the plastic chain/sprocket cover to the control plate with the 2 hex head bolts. Slid that assembly behind the brake cylinder and lined up the control plate holes that go to the frame. I attached the control plate to the frame loosely with just the top mounting bolt (the short 14mm). I then installed the plastic brake switch slider peg and the brake pedal pivot to the control plate. Then I secured the brake cylinder to the control plate with the two hex head bolts. Mind you, I still haven’t fully tightened anything still aside from the slider peg and the brake pedal pivot. Next, In order to get the brake pedal mounted with the spring over the pivot point, I had to remove the brake pedal with the pin and retaining clip (push the clip forward and then lift the top part of the clip and slide out). The brake pedal needed a little help from a small hammer to slide in. Once that was on, I attached the foot rest bracket to the control plate and frame with the other 14mm bolt (still not fully tightening) and then the hex head that goes through the footrest mount and into the brake pedal pivot (tighten this one). Attach the footrest. I had to use a screwdriver to sort of pry the spring to line up the pin. Now you can press down on the brake pedal to reinsert the pin and retaining clip for the brake pedal. It’s all back together now and everything can be tightened. Lastly, just place the brake pedal switch on the slider pin and move it to where it is not engaged until you press the brake. Secure it with the last hex head bolt. Check that the brake light works and that the brakes work. Not super technical, feel free to reach out with questions! I have pictures and once I figure out how to upload them, I will.
Hi @22T100Jon - UK T120 rider here. Just wanted to thank you for this very comprehensive post and instructions, which has been extremely helpful to me in fixing this very same problem. My T120 suffered exactly the same as your T100 - went over on its right side and the brake pedal took the impact, snapping the control plate just like yours. I suspect that this is a relatively common problem so hopefully others will benefit like me from the detailed step by step instructions you shared. I don't have anything to add to your post, but I might add a few pics of my own pointing out visually some of the details you mention. Really appreciated !
Yes some very helpful notes there and its great of @22T100Jon to take the time to photograph and publish all the info. Thanks mate
