Tip & How-To about Motorcycles

Loose gear levers.

Worn splines on gear levers and shafts always result in loose levers or broken off bolts. When pinch gap has to be widened, (do not put any spacers between lever and shaft-it never works) the bolt entry angle must change or bolt will bind and snap before closing onto shaft. Turn the bolt into thread side to start of gap as protection for thread so you can elongate or drill larger diameter entry hole.

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shift lever

Possibly the lever's locking bolt thread has stripped or the thread on the bolt is worn. Another aspect is the splines in the lever are shot and/or the splines on the gear change shaft are badly worn. Remove lever and check the splines on both shaft and lever also check around the lever fixing section for any cracks. Check the threaded section of the lever with a brand new bolt the bolt should be easy to turn in and out by finger and should have no side to side play. When refitting the existing lever or a new one make sure the lever is a good fit on the gearbox shaft splines before you tighten the bolt.

Mar 29, 2014 | 1997 kawasaki VN 1500 Vulcan Classic

1 Answer

shifter broke

Keep your fingers crossed that it is simply a loose pinch bolt on the shift arm. To check, look closely at the shift shaft end as you move the shifter up and down. If the shift shaft is not moving with the shift lever, the pinch bolt may be loose, or more likely, the splines have worn out on the shifter due to a loose bolt. To fix, grab a 10mm wrench and loosen and remove the pass-through bolt that is on the shift lever and replace the shift lever. I provided a link to a used one on eBay for $15. If the splines on yours are good and the bolt is tight with the shift shaft moving properly, then the internal shift fork is damaged which will require a teardown. 91 Kawasaki EL 250 EL250 Eliminator SHIFT LEVER

Mar 05, 2014 | kawasaki Motorcycles

1 Answer

removing gear lever Kawasaki KX 125 motorcross-cant get the lever to come off, just hangs loose

Does it have a pinch bolt? If so undo and remove the pinch bolt, if the lever doesn't slide off you will need to pry the pinch part of the lever apart. It should then slide off. If it is worn it will hang loose, you will need a new lever, also check the splines on the shaft.

Oct 24, 2013 | kawasaki KX 125 Motorcycles

1 Answer

gear shift loose. How can I tighten so that this will stop coming loose? I tighten & tighten until I break the bolt.. Any advice?

You could buy a new gear lever, if the shaft is in good condition, or you could widen the gap in the gear lever by cutting it with a hacksaw untill you have removed aprox 5mm thus allowing you to clamp up the lever, tighter on the shaft

Apr 14, 2011 | 1973 Honda CB 350 F0

1 Answer

loose gear selector

the lever itself? is it the type with the 10mm bolt going through the lever (into a splined shaft)?
if so then either the thread's gone in the bolt/lever or the splines have gone on the shaft, otherwise it's the gear selector shaft/bearings within the box.
Hope this helps

Mar 29, 2011 | 2003 Suzuki GZ 125 Marauder

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