Dominator gear lever slipping on shaft...

[bigr1979]

Hi All,
Just got a '89 Dominator from my brother, all seems well apart from riding it home the gear lever started sliding on the shaft.

I have taken it off and had a look at it and unfortuantely the spline on the bike is buggered and I cant get the gear lever to grip.

I did try and drill a hole through the lever and the spline to fix it that way but the spline is too hard and I cant drill through it.

I have read the other posts on this but I just wanted to ask what the best idea to fix it would be without replacing the spline, my options atm are :-
A- get the gear lever welded on
B- was wondering if something like locite super steel would be good enough ?

Rich.

[AlanH]

You missed out an option...

C. Replace the shaft and lever.

[bigr1979]

Well I know there is that option but im really poor at the moment and the bike only cost £500 so I was just looking for a cheap as possible fix

[dr155]

Had this happen about 3 years ago , & the local 'bike shop tack-welded a new lever on , cost about £25 , and its still on there ....

The only drawback is if you ever need to dismantle the engine , so if you have any other work planned , might be as well to get it done now .

[Mervinh]

Have yuo had a good look a the shaft spline?? clean it up and se just how bad the splines are, then get a new block from my mate Dave gear lever block and weld on
merv

[AlanH]

This sort of thing is notoriously difficult to fix. Liquid metal doesn't do the job for any length of time. Welding it is an option but then when you want to get it off you have to cut it off. Sometimes there are just enough splines left on the shaft for a new lever to grip it but it will wear rapidly.

From a breakers, the shaft will probably be around the £20 mark. Someone on here may even have a spare one. Add a lever to that and factor in a clutch cover gasket and it's not a massive repair cost if you do it yourself.

[dr155]

Apparently , in my case , I had made the whole thing worse with my "Weekly analy-retentive blow-over with WD40" .
Heigh ho !

[StumpyFingers]

Get a tighter fitting lever from a c90 or similar.

[bigr1979]

Cheers for the info guys

A gear lever off a c90 ? Is that still likely to be ok even if the shaft it knackered then ?
It cant be that hold to get a gear lever off an old c90 can it ?

....Hmm just looked at those c90 levers on ebay, dont like the look of them, im thinking now just get it welded.
Are there any real issues I should know about getting it welded (apart from the obvious if i needed to take it back off) that I should know about ?
Or is it going to be as easy as pop into a garage hopefully on lunchbreak and get a blob of weld popped on and job done ?

[Mervinh]

This sort of thing is notoriously difficult to fix. Liquid metal doesn't do the job for any length of time. Welding it is an option but then when you want to get it off you have to cut it off. Sometimes there are just enough splines left on the shaft for a new lever to grip it but it will wear rapidly.

From a breakers, the shaft will probably be around the £20 mark. Someone on here may even have a spare one. Add a lever to that and factor in a clutch cover gasket and it's not a massive repair cost if you do it yourself.

Alan factor in a full gasket set might as wel do the rings and cam chain and the cam chain slides while you are in there it is a engine split job on the dommie to do the gearchange shaft i know i just stripped a SLR mill
Merv