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Sloppy Shift Lever, '97 ZX-11

J

JMHJ

Forum Mentor
Super Site Supporter
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.
 
Lever Pic number 2. To left of inner washer is the hex part of the stud.
 

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

Dkc8Hni.jpg


qnEEilD.jpg
 
I have a lathe. If you can make a proper sketch of the stud, I may be able to make one.
 
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 :rolleyes:

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

Click image for larger version Name: Resized_20210808_141903.jpg Views: 0 Size: 55.9 KB ID: 1729393
 
Nessism said:
I have a lathe. If you can make a proper sketch of the stud, I may be able to make one.
Click to expand...

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.
 

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Another view. Message with 15+ characters.
 

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Shifter just slipped on there. Can probably see the gap.
 

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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 ;)
 
unfocused said:
I should add, I loved my Zx-11's. Fast and fun !!!
Click to expand...

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:
Suzukian said:
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 ;)
Click to expand...

My efforts at shimming or filling the gap around the stud aren't working out too well. Haven't tried metal yet. Tried one washer that was just a bit thicker too, but the clip wouldn't go on, lol. Going to get the stud specs to Nessism and see what he thinks.

It's rideable; tested it tonight in miserable heat, but it shouldn't be like that.
 
I'm a little at a loss. If it's worn on the shaft, a washer wouldn't make a difference, just like having the right one would only hold the ends tight, and prevent you from feeling any slop that's there. When I posted "Shim", I mean around the shaft, to tighten up the hole. Then any washer would do. I guess I don't understand by what you mean by "sloppy". ;)
 
No, you got it. If the washers took up all the space horizontally, there would only be undesired "play" up and down (essentially). As it is, if you looked at the end of the shifter (with the rubber) from the front of the bike, you could see it move around in something of an egg shape (it has play every which way).

This doesn't look like wear to me. It's weird.
 
There is a NOS stud on eBay. Seller in Poland, but so what? International shipping will have it to you in a couple of weeks. I didn't look, but think it likely that you can buy a new shift lever also. The only other way you are going to fix this right, is by a machinist's solution.
 
JMHJ said:
No, you got it. If the washers took up all the space horizontally, there would only be undesired "play" up and down (essentially). As it is, if you looked at the end of the shifter (with the rubber) from the front of the bike, you could see it move around in something of an egg shape (it has play every which way).

This doesn't look like wear to me. It's weird.
Click to expand...

Depends on mileage. Normal wear and tear plus vibration does a lot of damage.
 
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