Gearhange shaft.

[Pussyhorse]

The gearchange shaft on my old ******* 650 is getting worn. The lever used to work it's way loose once a month or so, but now it's lucky if it holds for a couple of days. Toyed with spot welding it as a bodge (until I need a new C&S set), but as it's summer I might as well use my GS for commuting and do it properly so it's fighting fit and ready for hack duties come the winter.

While I'm at it I'll investigate why it's drinking oil. Compression isn't bad and it doesn't smoke, so hoping it's just the valve stem seals.

I haven't got any manuals for it or owt. Is it just a case of removing the clutch basket and pulling the shaft out (like on most motors) or is this lump a bit different?

Cheers

[Northy]

I assumme that the spines are worn on the shaft ?
if so another trick is to take say 1mm from then surface on the clamping bit of the lever. ie the gap is bigger ... so it allows the lever to clamp onto the shaft , rather than rely on the splines .

Hope you undertand this .....a picture is worth a 1000 words or 1000000 of my words

Northy

[YEN_POWELL]

I alway take the lever of and use an angle grinder down the split of the clamp. This widens it as mentioned above. Finally before clamping it up I use some thread lock glue on the splines. My DR350 suffers from the same problem you described.

[Muckybill]

You could try drilling and tapping into gear lever and shaft and screwing in a grub screw. Centre punch where the two meet and drill for the the size of tap you will be using. For M3 drill size for tapping 2.5mm. For M4 drill size 3.3mm, then run a tap down. Once the grub screw is in the lever can't rotate on shaft and it can't slide off.
I have tried inserting a diagram, don't know if it will work.



DaveS - You're trying to upload the wrong file types. They have to be jpg's that you upload.

Bill

[Muckybill]

Nope diagram didn't work

Oh well back to the drawing board

Bill

[Pussyhorse]

Cheers guys. Never really thought of just removing some material from the split. Worth a go.

I don't have an angle grinder, but now I have a good reason to go out and buy one. Cool.

[Northy]

Use a Hacksaw ........a grinder may be a bit OTT.

Northy

[Pussyhorse]

Yeah, but it'd be more fun.

I suppose if I nip the ends together I can get in there with a hacksaw.