I think i have actually buggered my bike up..

[Eddie Hitler]

Splines on the shaft must have worn down.

3 gear levers later and its still happened, cant really be anything else.

Rough price/procedure to replace shaft?

[NSR Mick]

Could be a simple as clutch cover off, clutch off, remove circlip or other retaining device, slide shaft out.

Get new shaft in hand and reverse procedure.
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If you dont like the way that I ride.......Stop trying to keep up!!!

[Eddie Hitler]

Ok cheers, it looked like it was seperate from the engine. WHat ill do it get a new shaft or something from Honda, with a new gear lever and get a small garage ive dealt with for a few years (very good) to get it donr properly for me.

Until i can afford it ill have to change gear with my foot vertical.. only way it grips is when the gear lever is /. Lol.

[stinkwheel]

Have you tried shimming round the shaft with some slices of beer can?

Failing that, if you have decided the shaft and lever are shagged and to be replaced, there is a horrible but effective bodge you can do.

Go out and buy a 4mm HSS drill bit (about £1.50) and put it in the freezer. Set the lever where you want it and do up the clamp as tight as it will go. Heat the area where it clamps as hot as you dare with a blowlamp.

Now drill into the bit where the lever joins the shaft. You should eventuall feel the drill starting to 'bite' once it has gone in a ways. Stop here, undo the drill chuck leaving the drillbit stuck into the metal and snap the end off.

Seen that fix work for a period of years. If it falls out, try hammering an iron nail into the 'hole'.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Eddie Hitler]

Sounds like a decent bodge ( ), it seems to work fine now i have change the position of the lever. Like i said it looks like /. But ill eventually get round to replacing what needs replacing as ill be seilling next year for a 600 when my restriction is up. I was worried i may have to replace the engine or something. So at least that worries gone.

[Pete.]

Maplins do a box of about 60 roll-pins for about a fiver. Set the position, drill right through and tap-in a roll-pin.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Eddie Hitler]

A friend of mine suggested welding the gear lever on.

Now when it sounds ideal as it will solve the problem 100% what after effects will i get? Eg not being able to take the chain off?

[Blau Zedong]

Welding the gear lever on is for neanderthals.

Consider that if it does need to come off you'll have to grind it and reweld it EVERY BLOODY TIME.
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

[Eddie Hitler]

Thats exactly what i thought.

Im going to give that roll pin technique a go when i get some dolla.

[Stalk]

Could perhaps try taking off the gear lever, cutting a thin slice out of the gap where the pinch bolt goes through to make the split bigger. Hopefully when you tighten the bolt up, the hole in the middle (where it goes over the shaft) will be smaller and will maybe grip better.

Just an idea, hope it helps.
Cheers,
Stalk.

[ZaphodBeeble]

[rotax81]