I was riding on the road to my house and noticed that I couldn't change gears. I realized the shift lever fell out. Luckily for me, it was just at the bottom of my driveway. The nut fell out of the bolt that secures it in place. I searched high and low for the thread size, but does anyone here know what size nut I need to replace it?
Also, I'm not sure how to remove the bolt from the lever. The lever is still connected with the ball/arms.
you need to loosen the bolt (part #11) on the tie rod (part #9) then turn the whole thing from the ball/arm thing all together ... that will separate the shifter from the rod
Also, I'm not sure how to remove the bolt from the lever. The lever is still connected with the ball/arms.
You don't have to disassemble the shift linkage. It's much easier to remove the pivot shaft from the shift lever. Use a 5 mm allen wrench to remove the button head screw and washer, which holds the shift lever to the pivot shaft. Use an adjustable wrench to hold the pivot shaft where the flat is on the threaded end. Before you put it all back together, clean and re-grease (even better, use anti-seize lubricant) the pivot shaft. Also, when you go to get a replacement nut, you want to ask for a Flange Nut. While your there at the hardware store, get a small tube of Loctite Blue 242 medium strength threadlocker (DO NOT USE RED LOCTITE*) to use on both the flange nut, and the threads of the button head screw. No more shift lever falling apart while motoring down the road.
* Red Loctite is a high strength threadlocker, and requires heat to disassemble fasteners that it is used on.
Last edited by MotoMike; 12-04-2012 at 01:24 AM.
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You don't have to disassemble the shift linkage. It's much easier to remove the pivot shaft from the shift lever. Use a 5 mm allen wrench to remove the button head screw and washer, which holds the shift lever to the pivot shaft. Use an adjustable wrench to hold the pivot shaft where the flat is on the threaded end. Before you put it all back together, clean and re-grease (even better, use anti-seize lubricant) the pivot shaft. Also, when you go to get a replacement nut, you want to ask for a Flange Nut. While your there at the hardware store, get a small tube of Loctite Blue 242 medium strength threadlocker (DO NOT USE RED LOCTITE*) to use on both the flange nut, and the threads of the button head screw. No more shift lever falling apart while motoring down the road.
* Red Loctite is a high strength threadlocker, and requires heat to disassemble fasteners that it is used on.
I used to Loctite threadlock fasteners on my bikes till many yrs ago I swapped to just Loctite Anti-seizeing every bolt or moving part I touch.
Simple, rustproof, lubricating, and NOTHING ever rattles loose.
main advantage you dont need to reapply once done.
I have an artists brush instead of the big brush in the lid.
Never even lost a dirtbike sidecover in yrs of enduo racing.
__________________
Team Gumby.
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I used to Loctite threadlock fasteners on my bikes till many yrs ago I swapped to just Loctite Anti-seizeing every bolt or moving part I touch...
Yeah, I use Anti-seize on nearly all of the fasteners and moving parts too... I still have been using a drop of the blue Loctite on a few of the nuts and bolts that rarely get taken apart... old habits die hard. I'm learning new tricks, though.
Shift Lever fell off
