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Sloppy hole, new bush required?

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A100man
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Joined: 19 Aug 2013
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PostPosted: 11:09 - 19 Oct 2020    Post subject: Sloppy hole, new bush required? Reply with quote

The gear lever on my XJ has a kind of rear set arrangement with a pivot shaft on the sprocket cover. I looks like the gear lever hole has ovaled a bit from long term thrusting.. The hole looks like it 'should' be 12mm ID.
anyone drilled one out and fitted a (new) bush?

Looks like I can get steel or bronze sintered or split in OD 14 or 16 mm
. the plan being to drill out with a pillar drill and press in with vice - thoughts?
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Islander
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PostPosted: 12:17 - 19 Oct 2020    Post subject: Re: Sloppy hole, new bush required? Reply with quote

A100man wrote:
The gear lever on my XJ has a kind of rear set arrangement with a pivot shaft on the sprocket cover. I looks like the gear lever hole has ovaled a bit from long term thrusting.. The hole looks like it 'should' be 12mm ID.
anyone drilled one out and fitted a (new) bush?

Looks like I can get steel or bronze sintered or split in OD 14 or 16 mm
. the plan being to drill out with a pillar drill and press in with vice - thoughts?


I see no reason it wouldn't work unless the removal of metal weakened the lever significantly. On the other hand, how available are they as spares from eBay or dealers?
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stinkwheel
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Joined: 12 Jul 2004
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PostPosted: 12:41 - 19 Oct 2020    Post subject: Reply with quote

I did it with the rear brake pivot on my VFR, worked wonders. I used a split glacier bush and a new trunnion.

I'm not entirely clear how the arrangement on yours works but it looks like there is a steel pivot shaft that screws into somewhere. Make sure that isn't worn too (they are cheap if it is). It's got a central groove for grease so I'd be tempted to use a solid bronze bushing.

You'd usually drill it to a hair under the final diameter then finish off the hole with a reaming tool (drills don't make round holes). You'll probably get away with it though. The final diameter would ideally be for an interference fit, so marginally smaller than the OD of the bushing. One way to achieve something close without a mill would be to drill it to the next drill size down then take the hole out to final diameter with a piece of emery cloth trapped in a slotted bit of tube in your drill (like a flap wheel).

If you go for a solid bush, heat fit it, don't press it.
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Riejufixing
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Joined: 24 Jun 2018
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PostPosted: 13:33 - 19 Oct 2020    Post subject: Re: Sloppy hole, new bush required? Reply with quote

A100man wrote:
The gear lever on my XJ has a kind of rear set arrangement with a pivot shaft on the sprocket cover. I looks like the gear lever hole has ovaled a bit from long term thrusting.. The hole looks like it 'should' be 12mm ID.
anyone drilled one out and fitted a (new) bush?

Looks like I can get steel or bronze sintered or split in OD 14 or 16 mm
. the plan being to drill out with a pillar drill and press in with vice - thoughts?

Should be fine. What's it made of? Can you post a picture of your hole? You might be as well off filing it out, depending on your drill and the lever's material.
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A100man
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Joined: 19 Aug 2013
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PostPosted: 15:12 - 19 Oct 2020    Post subject: Reply with quote

Thanks all - can't be sure what it's made of looks like chrome plated steel but who knows..

.. new ones are NLA on CMSNL and I think all used ones will be as bad as I have.
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600
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