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Wobbly Shift Lever Fix

Nessism

Nessism

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The shift lever on my 1000S project bike was wobbly due to wear on the pivot stud and inside the shift lever bore. A quick check showed about .015” clearance when it should have been about .003”.

The frame stud is 12mm (.472”) and welded to the frame. After consulting with a machinist friend we decided the best fix would be to replace the pivot stud with a shoulder bolt (.500”) and ream the shift lever oversize to match. We could have bushed the shift lever back to 12mm but ? inch was much easier in terms of finding the bolt and reamer.

A drill guide was fabricated to assure the hole was drilled straight using a block of aluminum and a slip-in hardened guide.

- Frame stud shortened
- Guide placed over stud
- Drill the hole – two steps, starting with small drill bit first
- Remainder of stud ground off
- Hole tapped
- Ream shift lever oversize (not shown)
- Install new bolt, after zinc plating

Turned out well; shift lever now is nice and solid feeling.

V008.jpg


IMG_1398.jpg


IMG_1401-1.jpg


IMG_1403.jpg
 
Last edited:
NICE! Can i send you these 1100E frames and have you do that?? LMAO! I wish I had the tooling to do so, looks like a very nice clean fix. Thanks Ed.
 
The correct tools and the knowledge to use them, goes a long way. :dancing:

Job well done, sir! ;)
 
btw Ed that bike looks filthy. Why don't you try cleaning it up once in a while eh? ;) :p
 
TheCafeKid said:
btw Ed that bike looks filthy. Why don't you try cleaning it up once in a while eh? ;)
Click to expand...

Ha ha Josh.:p The bike is dusty, which always shows though in the photos, but other than that it looks killer. The dang Por-15 engine paint is developing a burned/yellow/brownish looking cast to it already which is not a good sign but other than that all is well. Only thing left to do is get the seat upholstered. I'm soaking the seat pan in some oxalic acid solution to derust it right now, then it will get some paint and off to the upholstery shop...as soon as I find one I like.:cool:

V004.jpg
 
Last edited:
hey Ed,

Bike looks great - nice work, as always...

have you ridden this one much?

mike
 
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