My shifter lever is wobbly!

[cableguy]

My shift lever needs help. There is quite a bit of slop at the pivot where the lever meets the frame, and the splined clamp at the transmission is fine. The heim joints at each end are definitely not as tight as they once were, but the problem is how much wiggle there is in the shift lever.

I searched, and found 2 fixes:

1) Shim it with a piece of aluminum can. Did that, and it helped somewhat but doesn't seem permanent.

2) Machine a new stud big enough to fill the hole in the lever. Not feasible because I don't have access to a lathe or anyone that can do it for me.

How far over bore do you think I can go before the arm gets weak? I was thinking that if I find a needle bearing to fit the stud, then ream the lever to fit the bearing, the clearances will be tight again, and likely stay that way. I just don't want to over-ream and weaken the lever. I don't think I want to grind the stud - it has a groove in the center that holds grease and that's probably good to retain.

Thoughts and suggestions welcome!

 

[Nessism]

Did you see this thread in the archives?
http://www.thegsresources.com/_forum/showthread.php?t=151707

 

[cableguy]

I'm happy to say yes I did. I searched quite a bit before asking what I figured to be a common issue. I was surprised to be unable to find much.

I should have taken a picture.

My setup is 2 pieces, with linkage connecting the lever to the splined connection. The pivot stud is removable. Here's the pic:

http://www.bikebandit.com/1986-suzuki-gs1150eg/o/m6011#sch263269

#40 mounts to threaded stud on frame
#38 is what is loose and wobbly

 

[Nessism]

Why don't you just buy new parts since the stud is replaceable? Part Shark has pretty good prices in my experience.

 

[cableguy]

Looks like I might be heading that way but the macgyver instinct is too strong to make that my default solution.