Any tips on tightening loose shift lever?

[hikermikem]

My 1100EX has a loose shift lever - I tried simply tighening it, but is still wiggles on the shaft (will actually pull off the shaft with the bolt in it).

Since the history of this bike unkown, I thoughgt perhaps the shift lever wasn't the correct one for the model, so I bought another "model-correct" one on e-bay. Same story, won't tighten competely around the the splines. In fact, the e-bay one was identical to the one I had...

So, the question is: what methods or tricks has anyone used to get these lever tight ?

Thanks,

mike

[Steve]

The fact that it comes off the shaft with the bolt in it tells me that someone has modified the shaft.

There should be a groove running around the shaft, about 10-15 mm from the end, through which the bolt will pass.
It should not be possible to slide the lever off with the bolt in place.

Now, to your problem of getting it tight enough. Are you able to tighten down the lever at all, or does it bottom out? If the ends of the lever are touching before the lever gets tight on the shaft, use a file, Dremel tool with a cut-off wheel, whatever, to enlarge the size of the gap so that you can draw it together more before they bind up.

.

[hikermikem]

The fact that it comes off the shaft with the bolt in it tells me that someone has modified the shaft.

There should be a groove running around the shaft, about 10-15 mm from the end, through which the bolt will pass.
It should not be possible to slide the lever off with the bolt in place.

Now, to your problem of getting it tight enough. Are you able to tighten down the lever at all, or does it bottom out? If the ends of the lever are touching before the lever gets tight on the shaft, use a file, Dremel tool with a cut-off wheel, whatever, to enlarge the size of the gap so that you can draw it together more before they bind up.

.

Thanks Steve,

Yeah I'm familar with that groove in the shaft that's supposed to capture the bolt - the shaft doesn't appear modified to my eyes, but who knows... the bike is still a mystery to me.

I was also thinking the same thing - remove some material from the lever "split" so it will tighten more around the spline. I was considering using a band saw to "open up" the slot, but your suggestions look good as well...

thanks,

mike

[posplayr]

The fact that it comes off the shaft with the bolt in it tells me that someone has modified the shaft.

There should be a groove running around the shaft, about 10-15 mm from the end, through which the bolt will pass.
It should not be possible to slide the lever off with the bolt in place.

Now, to your problem of getting it tight enough. Are you able to tighten down the lever at all, or does it bottom out? If the ends of the lever are touching before the lever gets tight on the shaft, use a file, Dremel tool with a cut-off wheel, whatever, to enlarge the size of the gap so that you can draw it together more before they bind up.

.

What he said; but it is kinda hard to beleive as the splines would be obviously worn/ground down for that bolt to "wiggle" off. Maybe a former PO used a puller to get it off after loosening the bolt . I was gonna say post a pic but not sure I could bear to look

[Zooks]

.......I was also thinking the same thing - remove some material from the lever "split" so it will tighten more around the spline. I was considering using a band saw to "open up" the slot, but your suggestions look good as well...

Just not too much or it might crack when you tighten it down.

[posplayr]

Just not too much or it might crack when you tighten it down.

In theory it should not matter as the shift arm clamps down on the splined shaft; but this is sounding more like a reinstall requiring JB weld or the like

[Steve]

I was considering using a band saw to "open up" the slot, but your suggestions look good as well...

I have found that you can only use what you have available.

I don't have a bandsaw.

.

[hikermikem]

What he said; but it is kinda hard to beleive as the splines would be obviously worn/ground down for that bolt to "wiggle" off. Maybe a former PO used a puller to get it off after loosening the bolt . I was gonna say post a pic but not sure I could bear to look

I'll try to post a pic Sun, after i get back from the Great White North (VT).

It doesn't look too worn to me though...

[hikermikem]

I have found that you can only use what you have available.

I don't have a bandsaw.

.

I have a band saw available to me at work... that's why I go everyday, to work on bike parts !

[morpheus666]

If the splines are ok, my thought is that a PO put on a slightly larger shift lever, hence the play.

[Steve]

... my thought is that a PO put on a slightly larger shift lever, hence the play.

Yeah, except for a statement he made in his original post ...

... so I bought another "model-correct" one on e-bay. Same story, won't tighten competely around the the splines. In fact, the e-bay one was identical to the one I had...

.

[hikermikem]

Sloppy gear shaft pic

I'll try to post a pic Sun, after i get back from the Great White North (VT).

It doesn't look too worn to me though...

Looking at the gear shaft end...






Gear shaft levers, one on left I opened up the slot, now it tightens...

[Macguyver]

Hmmm. What if...

Is it possible that someone changed out the shaft with one from another GS model?
Maybe someone swapped out the transmission with a replacement from a different year/size?

I don't know if they have different sizes on the different model/years, but it might explain the mystery.

Then it's a simple matter of getting a shift lever that was meant to work on the smaller diameter shaft.
I know I would feel better about using the correct one instead of using one that is stressed a bit more than it should be.
Increases the chances of the metal failing under load, I think.

Does anyone know if there is a smaller GS shifter shaft size? Perhaps from a smaller displacement engine with a compatible transmission?

I have seen a similar situation with steering knuckles on cars.

Hope this helps.

[hikermikem]

Is it possible that someone changed out the shaft with one from another GS model?
Maybe someone swapped out the transmission with a replacement from a different year/size?

I don't know if they have different sizes on the different model/years, but it might explain the mystery.

Then it's a simple matter of getting a shift lever that was meant to work on the smaller diameter shaft.
I know I would feel better about using the correct one instead of using one that is stressed a bit more than it should be.
Increases the chances of the metal failing under load, I think.

Does anyone know if there is a smaller GS shifter shaft size? Perhaps from a smaller displacement engine with a compatible transmission?

I have seen a similar situation with steering knuckles on cars.

Hope this helps.

I suppose anything is possible... I know nothing of this bike's past.

I does look like it was down on that side at some point over its life.

The shift lever with the opened up slot tightens up pretty well however, so at this point - problem solved.

[Macguyver]

Good job.

Done and done.
Good job all around.
What's next on the list?