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Sloppy Shift Lever, '97 ZX-11

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    Sloppy Shift Lever, '97 ZX-11

    The lever rides on a stud and works a rod that actually does the shifting (It's not a splined thing that goes directly on the shift mechanism thing like I remember at least one of my GSs having). It's got a washer on either side of it (2), and is held on by an e-clip that goes in a groove on the end of the stud.

    My "problem" is that it's loose on the stud. I took all the measurements a few months ago but can't remember where I put them. This all started when it fell off while I was riding, and all that was left was one washer on the stud, which is is screwed into part of the bike. I didn't know what was there before since I didn't pay much attention, but the parts I named is all the diagram shows.

    I tried to find like a bushing or something to put on the stud to take out the slop, but the clearance is smaller than you'd think, just judging by the amount of play it has.

    So I ordered everything from Partzilla (stud, washers and e-cilp; lever itself is discontinued). I got the washers and e-clip, but the stud has been on backorder for months. I only ordered that too since I thought it might have a sleeve or something on it that mine doesn't.

    When I finally put it back together with that stuff (I had it reinstalled with some temporary stuff and an e-clip that wasn't exactly right for a while), it didn't have noticeable slop - the way it all fit together sort of held it in place, even though there is clearance between the shift lever hole id and the stud od.

    That was some weeks ago, and it has slop again! This seems simple, but I'm missing something. I don't really notice it riding, but it doesn't seem right.

    I'll post some pics later.

    #2
    Lever Pic number 1.

    Attached Files

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      #3
      Lever Pic number 2. To left of inner washer is the hex part of the stud.
      Attached Files

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        #4
        Long post for such a stupid simple thing, but yeah. It's like the inside of the lever where it slides over the stud isn't the same diameter throughout maybe. Nothing looks to be worn crazy really unless I didn't look close enough.

        Pics are lousy too, sorry.

        Comment


          #5
          Originally posted by JMHJ View Post
          Pics are lousy too, sorry.
          Yeah, a wee bit dark. Black on black. I can't really see, does it have a rearset linkage?
          1982 GS1100E V&H "SS" exhaust, APE pods, 1150 oil cooler, 140 speedo, 99.3 rear wheel HP, black engine, '83 red

          2016 XL883L sigpic Two-tone blue and white. Almost 42 hp! Status: destroyed, now owned by the insurance company. The hole in my memory starts an hour before the accident and ends 24 hours after.

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            #6
            This is what I did...https://www.thegsresources.com/_foru...hift-lever-fix

            Ed

            To measure is to know.

            Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

            Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

            Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

            KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

            Comment


              #7
              Nice, thank you.

              I tried a cap from a Crayola marker (lol), the thinnest end, slipped over the stud, but I still had to sand it to make it even thinner. That worked for a while, but then I started having trouble getting it into first; it wasn't returning freely to the (at rest) position I think. I had oiled it, but the plastic just wasn't as slippery as like nylon or something would've been.

              Amazing how much it moves around, but you can't hardly find anything thin enough to go between the stud and shifter.

              Comment


                #8
                If it helps anyone visualize what’s going on, I doctored the pics a bit for clarity.



                Rich
                1982 GS 750TZ
                2015 Triumph Tiger 1200

                BikeCliff's / Charging System Sorted / Posting Pics
                Destroy-Rebuild 750T/ Destroy-Rebuild part deux

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                  #9
                  I have a lathe. If you can make a proper sketch of the stud, I may be able to make one.
                  Ed

                  To measure is to know.

                  Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                  Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                  Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                  KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                  Comment


                    #10
                    Funny you should ask about this. I have '93 ZX-11 gearsets on my GS. I'll look this weekend and see what I did to fix mine.

                    Pic for the hell of it

                    I should add, I loved my Zx-11's. Fast and fun !!!

                    Resized_20210808_141903.jpg
                    Current:
                    1993 ZX11 - 2nd build in progress
                    1977 GS750 (710 is getting closer)
                    1998 Kawasaki Voyager - selling
                    1998 Chevy C2500
                    1999 Rav4

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                      #11
                      Originally posted by Nessism View Post
                      I have a lathe. If you can make a proper sketch of the stud, I may be able to make one.
                      Thank you... I'll attach another pic or two, maybe better (I know that's not enough). I've got another idea or two I might try. Checked with Partzilla again, and no word on availability for it yet (not that the exact same thing'd do me any good).

                      TY to Rich for trying to help out my other pics.
                      Attached Files
                      Last edited by JMHJ; 08-25-2023, 08:59 PM.

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                        #12
                        Another view. Message with 15+ characters.
                        Attached Files

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                          #13
                          Shifter just slipped on there. Can probably see the gap.
                          Attached Files

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                            #14
                            It seems that the washer was holding it square. I'd try wrapping some shim stock and see if tightening up the shaft in the hole solves the problem. It seems the other washer was holding a worn shifter square to the shaft. IMHO

                            Comment


                              #15
                              Originally posted by unfocused View Post
                              I should add, I loved my Zx-11's. Fast and fun !!!
                              Yeah, I like mine pretty well too. Wasn't looking for one specifically, it's just what came up in my price range and in the style I was looking for. Kinda wanted something my boys couldn't trifle with the old man on too. This fits it. Not that I'm going to ride like that with them, but just the fact that I could is enough.
                              Last edited by JMHJ; 08-26-2023, 09:41 PM.

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