Pharks gear lever...

[Pharkmeh]

I thought for clarity I'd start my own thread rather than continue hijaking this thread as I am a little unsure of the best way to progress...

as Ive mentioned my lever has been traveling up the spline since I owned it... and rather than lose the thing altogether I need to fix it...

the bolt has been fastened to the point of being stripped...

as you can see below it gets to the point of dropping off



although the nut is stripped as you can see I noticed that the lever is actually threaded half way through - the top half as we look at it....





good thing I decided to do something about it cause i was actually able to remove the whole lever without removing the bolt...

so much for splines and valleys...

however, as indicated by steve in the other thread the reason it came off so readily was indead a more significant problem...

as you see in the piccy the end of the shaft appears to be bent, thereby narrowing the valley - some how rather than locking the lever in, it allows it to travel past ????



I dont have time or money to dissasemble and replace...

and I need it on the road for work...

and simply replacing the bolt wont change anything since the bolt itself has no wear or damage where it sits between the splines...

I was thinking of trying to drill out the bolt hole without re-tapping it and using a larger bolt in the hope the larger circumference might help grab...

as well as following advice in the earlier thread on filing back the gap that exists in the sleeve allowing me to pull it together tighter...

only problem with that is it looks like I need a hacksaw as getting anything other than a nail file in that gap would be impossible...

I would be grateful for any thorts you lot might have....

cheers

Phark

[earlfor]

I've had that problem before. I cut a shim from an aluminum soda can to wrap around the shaft. Spread the slot in the lever with a screwdriver as much as you can so you can get nearly a 360 deg wrap with the aluminum pop can sleeve over the splined shaft. When you tighten the bolt down, it will clamp tightly enough that no valley is needed. (you can reduce your parts costs by buying a local,non major brand soda to get the aluminum can) :-) :-)
Drinking it first is up to you. :-)

Earl

[Pharkmeh]

I've had that problem before. I cut a shim from an aluminum soda can to wrap around the shaft. Spread the slot in the lever with a screwdriver as much as you can so you can get nearly a 360 deg wrap with the aluminum pop can sleeve over the splined shaft. When you tighten the bolt down, it will clamp tightly enough that no valley is needed. (you can reduce your parts costs by buying a local,non major brand soda to get the aluminum can) :-) :-)
Drinking it first is up to you. :-)

Earl

Geebuz - thanx for the tip m8

I just knew if I had to get mekanikle with it - she was gunna regret it..

got beer cans aplenty - just need a new bolt...

cheers m8

let ya know how it goes

phark

[earlfor]

Glad you've saved empties. I would hate for you to have to drink a whole beer at one time just to get a little piece of aluminum.

Earl :-)

Geebuz - thanx for the tip m8

I just knew if I had to get mekanikle with it - she was gunna regret it..

got beer cans aplenty - just need a new bolt...

cheers m8

let ya know how it goes

phark

[Pharkmeh]

Glad you've saved empties. I would hate for you to have to drink a whole beer at one time just to get a little piece of aluminum.

Earl :-)

empties be beggerd - it could take 5 or 6 cans to find the right one....:-\"

[Ninja_Lancer]

Phor phark sake phix the pharking thing.

[Cruzr]

I just realized that this is in the "Technical Info" section....thank goodness! That means the topic isn't about what I was afraid it was about!!! LOL

[Pharkmeh]

I just realized that this is in the "Technical Info" section....thank goodness! That means the topic isn't about what I was afraid it was about!!! LOL

no - that lever is healing just fine thank you very much...



although I did get a hightensile bolt to replace the stripped stainless left by the PO

all I gotta do now is get to the bottom of the carton to find the perfect can....

[emjay]

... all I gotta do now is get to the bottom of the carton to find the perfect can....

Just as you always find what you've lost in the last place you look, the perfect can will be the last beer in the carton...

[Pharkmeh]

thx Earl

Just as you always find what you've lost in the last place you look, the perfect can will be the last beer in the carton...

you are so right m8....


ya know I had to finish meh last 6 cans of beer only to find the perfect fit was in fact a can of Bundy Rum...

what was I thinking...

sillyness aside

Thx Earl m8... =D>

• split the gap a treat
• threw the bundy can sleeve in there - pressed it a lil
• cranked the new hightensile bolt up with a lil lock tight

looks to have grabbed really well and looks tidy

wont know till I get it out for a ride... bit dark now incase I got it a lil wrong and the thing drops of anyway lol...
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gr8 that you guyz in the know reply to these lil probs as well as the more techincal stuff...

cheers


Phark

[beby99]

Thx Steve m8... =D>

• split the gap a treat
• threw the bundy can sleeve in there - pressed it a lil
• cranked the new hightensile bolt up with a lil lock tight

looks to have grabbed really well and looks tidy
Phark

Must have searched for one to many cans....it was Earl that posted yer answer #-o

[Pharkmeh]

you are so right m8....


ya know I had to finish meh last 6 cans of beer only to find the perfect fit was in fact a can of Bundy Rum...

what was I thinking...

sillyness aside

Thx Earl m8... =D>

• split the gap a treat
• threw the bundy can sleeve in there - pressed it a lil
• cranked the new hightensile bolt up with a lil lock tight

looks to have grabbed really well and looks tidy

wont know till I get it out for a ride... bit dark now incase I got it a lil wrong and the thing drops of anyway lol...
.
.
.
.
.
.
.
gr8 that you guyz in the know reply to these lil probs as well as the more techincal stuff...

cheers


Phark

Must have searched for one to many cans....it was Earl that posted yer answer

you sure your noot the one drinkin....:-\" O

[beby99]

.....lol..

[Planecrazy]

Good Humor! Now, back to the serious issue at hand for just a moment...

Does the shift lever go all the way on to the shaft before tightening the bolt or does the unwanted bend prevent this?

If it DOES go all the way on, in addition to the fix already suggested you might also want to drill a small hole through the center of the entire assembly (once it's properly assembled) and put a cotter pin through it to prevent it from working its way back toward the bent part (much like the cotter pins on the axles keep the nut from backing out).

It probably got bent in the first place by many hard shifts while it was sitting half on and half off the shaft. We certainly don't want that to happen again! A well placed cotter pin will act as a safety in case the other fix degrades over time...

Good Luck!

Now back to our regularly scheduled Hi-Jinx!

[Planecrazy]

By the way, you asked what caused the "valley" in the back of the splined shaft ... on my bike (and every GS I've seen) the "valley" is machined all the way around the shaft at that point, and on my bike the shift lever bolt is in the rear ... not the front, so I'm guessing your shaft is supposed to be that way (although it obviously shouldn't be bent)... Do you know if that is an OEM shift lever?

Regards,