Gear Shift Lever - removal tips

[Scott]

Hello everyone.

Anyone got any tips to remove the gear shift lever?

The pinch bolt had sheared, I have managed to remove the thread that was left in the lever using pliers; however, when trying to remove the lever from the splined shaft it only comes off the shaft about a 1/4 of an inch and then refuses to budge?...I've only tried pulling it i.e. not used any leveredge with tools etc.

I am loathe to use too much force and thought I'd run it by you all first.

Additionally is there a part number for the pinch bolt?...or is it a 'bog standard' bolt?
Looks like 20mm to me.

Thanks in advance.

[squirrelciv]

If you're sure all the old bolt is out, then put a screw driver in the slot of the gear selector and give it a tap to open up the grip, that should do it. Not too much mind, we don't want metal fatique. If there is any bolt left in there, things will not budge as the shaft has a groove machined around it so the bolt acts as a locator. If you have anything in there it's drilling time I'm afraid
Bolt is a standard metric course thread M6 (I think) so any thing will do.
I wouldn't reccomend levering off against the crankcase if things are troublesome, rather better would be a small sprocket puller, but things usually come apart if the grip is opened up with a screwdriver.
Best of luck

[cafe650]

wot he said.

[Scott]

If you're sure all the old bolt is out, then put a screw driver in the slot of the gear selector and give it a tap to open up the grip, that should do it. Not too much mind, we don't want metal fatique. If there is any bolt left in there, things will not budge as the shaft has a groove machined around it so the bolt acts as a locator. If you have anything in there it's drilling time I'm afraid
Bolt is a standard metric course thread M6 (I think) so any thing will do.
I wouldn't reccomend levering off against the crankcase if things are troublesome, rather better would be a small sprocket puller, but things usually come apart if the grip is opened up with a screwdriver.
Best of luck

That's great thanks.
I am confident all the bolt is out, I'll check with a small piece of wire through the hole.

Cheers

[Scott]

Great tip with the screwdriver.

Gear lever off, cleaned and replaced with a new bolt (for free) from the local bike shop.

I did notice thought that the splines are getting really worn on the shaft that the gear lever clamps onto

What options are there if/when those splines are completely knackered?

Is it a nightmare to replace the shaft?

[Rubberchicken]

In short: yes.

A new lever with fresh splines will still work pretty well on a worn shaft, but the trick is to saw/grind a bit out of the pinch hole. With the stock lever it's pinched closed, so you can't really tighten it properly.

Check out this picture.
The lever there isn't tight on the axle, but on itself.

[squirrelciv]

In short: yes.

A new lever with fresh splines will still work pretty well on a worn shaft, but the trick is to saw/grind a bit out of the pinch hole. With the stock lever it's pinched closed, so you can't really tighten it properly.

Check out this picture.
The lever there isn't tight on the axle, but on itself.

Quite right RC Best way to do this little opperation is to hold the grip shut in the vice (just) and cut down through the slot with a hacksaw. Might take a couple of goes as the blade is only about 1mm thick, but you'll get there

[Rubberchicken]

Or alternatively, put the lever in a vice and use the saw to saw off a few mm (on the non threaded side!).

[McFly]

Check out this picture

Spot the new bit...!

[Scott]

Thanks for the replies guys.

It's OK for now...I'd already carried out this tip (with the hacksaw) so when I tightened up this time around its gripping pretty well.

I'll just make this one of my weekly checks (along with the oil).