Topic: Gear Lever

[Speza]

My gear lever keeps falling off.
I have replaced the clip and the washer, but it still happens.

Any ideas beyond drilling a hole in the shaft and sticking a pin in?

[Scott S]

 Clip and washer?
 What bike?

[ekpent]

Yes- that should be a pinch fit with a bolt on the spline shaft.

[Speza]

Ooop's should have mentioned bike, 400/4 F

[Speza]

It is a 400/4 F, the gear lever is located on a shaft, then links to the splined bit with a couple of ball joints.

[flybox1]

[01Thomas]

On my 400F I had the same problem. I solved it by drilling a hole through the shaft in the groove where the clip goes - and then I assembled iut with a splitpin instead of the circlip. Looked like a factory job.

[Speza]

Thanks for that.
The picture has given me a bit of a clue.
Item 22 that fits on the splines, is the wrong way round, the ball joint is on the inside, I will try reversing it.

Cheers

[Speza]

Yes, that is my last resort.

Cheers

[Bodi]

If the shaft groove is so badly worn that the clip falls off, you can try making it a bit deeper with a "jewellers" edge file or thin saw blade. Drilling and tapping the shaft end for a retaining washer and screw is an option, that would probably look better than a cross drill and small split pin? The part with the pin (50641-377-000B) is basically unobtainable new, and used 400F parts are uncommon - plus their quality is not reliable. You can try Ebay...

[scottly]

Make sure the clip is installed the right way; they have one side with rounded edges and one side with sharp edges. The side with sharp edges should be facing out.