Gear Lever

[Gubb]

So after my recent stack, the main part of the minimal damage to my bike was the Gear Lever. The actual lever survived no worries, but the 'pedal' part of it snapped off, and got lost.

Question is, I can order an entire new lever for $100, or is it OK, and will it pass a WOF if I place a bolt through the lever to act as the pedal, and somehow secure it?

Is this safe, or a stupid idea? Any suggestions most welcome.

[Ixion]

Been done many a time. No WoF issue so long as it's secure. Put a bit of rubber hose over the bolt, and you'd be hard put to tell.

[Gubb]

Cool, so what's the best way to secure it? Put the head end on the engine side of the lever, with a nut attaching it to the lever, and another nut on the end to make it a bit more blunt?

I'm not really a DIY fiend, but I am trying to learn.

[Ixion]

Take one bolt. Two nuts , two smallish plain washers,two slightly larger ditto, one spring washer, one bit of black rubber hose .

Assemble - slide one plain washer onto the bolt and butt up under the head . Slide the length of rubber on, then the second small plain washer. Then the first nut , and tighten the nut on the bolt until the rubber is just compressed (you're going to have to use your judgement about lengths here ). Leave enough of the thread showing to put it through the hole in the lever , plus a bit.
Now put first plain washer on the bolt (up aginst the nut) and slide the bolt into the lever hole. Second plain washer on the back of the lever, then the spring washer , then the second nut, spanner on the first nut and tighten the second nut good and tight.

Best to use a high tensile bolt, or stainless . From Supacheap.

[Gubb]

Legend, cheers a metric butt-load.

Will post pics once my hand has healed up and I can make the repairs.

[Patch]

Been done many a time. No WoF issue so long as it's secure. Put a bit of rubber hose over the bolt, and you'd be hard put to tell.

Take one bolt. Two nuts , two smallish plain washers,two slightly larger ditto, one spring washer, one bit of black rubber hose .

Assemble - slide one plain washer onto the bolt and butt up under the head . Slide the length of rubber on, then the second small plain washer. Then the first nut , and tighten the nut on the bolt until the rubber is just compressed (you're going to have to use your judgement about lengths here ). Leave enough of the thread showing to put it through the hole in the lever , plus a bit.
Now put first plain washer on the bolt (up aginst the nut) and slide the bolt into the lever hole. Second plain washer on the back of the lever, then the spring washer , then the second nut, spanner on the first nut and tighten the second nut good and tight.

Best to use a high tensile bolt, or stainless . From Supacheap.

Yup wot he said - fark, you did bang your nut good didn't ya? 'tis a cheap trick this one. Might have to ride your way an show u proper like how its done.

How is ya hand anyhow?

[Gubb]

Mate, any help, as always, would be much appreciated.

Hand is getting better, flake fractured the 3rd, and cracked the 4th and 5th Meta Carpels. Bruises and most of the swelling are gone now, should only be in this damned brace thing for another week and a half or so, then onto a soft sleeve thingy, which means I can ride again!

[Gubb]

Don't. If you fall off and rebreak it, it'll take a whole heap longer to heal the next time round, and optentially it'll come with complications meaning it never heals properly. And that's not cool. Lax up, drink some beer, let it heal

'tis all good, 'twas the Doctors that said I can get rid of it in a week or so. Also, no beers, doesn't mix with the medication!

Can't figure out what i'm gonna do first, drink a beer or go for a ride!

OH THE HUMANITY!

[FROSTY:Me]

if youve got that kinda time why not rip it off and get the shifter pin welded up propperly

[Gubb]

Don't have it, got lost in the confusion. Only noticed it was missing well after the crash, by which time, it was long gone.

[Gubb]

Got bored in the Waitangi day sun. I figured everyone else was out riding, so I had to have a bike fix anyway.

Managed to pick up everything I needed at Bunnings.
I bought 4 washers, 2 nuts, 1 bolt, 1 piece of rubber tube (5cm), 1 piece of garden hose (5cm).

Drilled a hole in the actual lever, coloured everything black with a Sharpie first, as I at least wanted it to not look like a rangi-mod. Placed a washer onto the bolt, followed by the rubber tubing, then the rubber hose. I wanted to put something underneath the hose as it was too loose by itself. Cut these to length with the Missus' good kitchen knife. Luckily she wasn't home to see this, as I would have ended up wearing the knife. Slid another washer on over the end of the hose, nut, placed it through the lever, another washer, and the final lock nut, and Presto! instant Gear Lever.

Total cost, $2.60 and 15 minutes. Much cheaper than the $100 it would have cost me to buy from a dealer.

Tested it, and the clearance between the lever and the pedal is sweet, works just like a bought one.

I enjoyed it too, there's an awesome sense of satisfaction that I just realised I had by fabricating my own one, rather than buying it off the shelf.

[Pancakes]

Nice work matey! Thats the spirit. Good luck with the hand.