I hate gear lever splines!!!!

[IronicCapers]

My only form of transport is being a lil bastard. dam gearlever has gone on me so gona av to gt a new one or do an annoying mod to the old one. Why cant they develope a newer method on which the lever is attached!!!

[Mr. Peanut]

YES I HATE SPLINES!!

Been through 2 on my Honda :angry: Im just going to put a bolt through it next, or a pin.

Funny that I've never had trouble with my kickstart spline though.

[Motu]

Zap it wiv the MIG,no more problem.If you want to remove it,use a disc grinder.It's not as bad as it sounds.

[IronicCapers]

yeah i would love to MIG it but its aloy on steel im fairly certain that you cant really do it

[Motu]

Duh,well there's your problem.What sort of fool would use an alloy lever on a steel spline? Some kid fresh out of design school who's never ridden or worked on a bike.

[Dodgyiti]

yeah i would love to MIG it but its aloy on steel im fairly certain that you cant really do it

Oh, no wonder!
What an absolute bastard thing that is always going to fail.
Built in spare parts earner, I bet the replacement is not cheap?
Can you not measure the spline diamater and go to the wreckers and look for a metal one?
It's ok for a kicker spline to clap out on you as you can at least bump start her, but a gear change is a whole new kettle of bitch.

[IronicCapers]

Duh,well there's your problem.What sort of fool would use an alloy lever on a steel spline? Some kid fresh out of design school who's never ridden or worked on a bike.

Ouch that hurt me rihgt here :brick:
I never got the lever or put it on

[Chipster]

On old mx'ers and trials bikes way back, we used to grind a flat onto the shaft, then spot a bit of weld onto the inside of the lever and file it back to mate the shaft. Will never turn on the shaft again, and you can keep the original locking bolt. Job's done. Might be a bit agricultural though, for sports bikes.

[vifferman]

I don't get it. What's the problem - is the spline on the in side of the gearlever stripped?

I haven't had a problem with this for years, not since I had crappy steel levers. The current one is aluminium alloy, and it's fine (apart from the fact it should be one with a linkage, not the crappy one Honda put on it; to micro-adjust it I have to heat it up and bend it).

[Grantasaurus]

Duh,well there's your problem.What sort of fool would use an alloy lever on a steel spline? Some kid fresh out of design school who's never ridden or worked on a bike.

I'm confused... last time I checked, steel was an iron alloy.

Do you mean aluminum/magnesium alloy on a steel spline?
It doesn't matter what materials the spline and lever are, as long as no material limits are exceeded. You just design for the weaker material, which in this case would be Al alloy.
There may be something more in this than just "bad" design. Splines are one of the better ways of mating a shaft.

I dunno, just my 2c

[Motu]

You sound just like an engineer with all theory and no practical experiance.However in the real world we have thuggish owners (not the owner in this thread of course) who tighten said 6mm gearlever bolt with a 1/2in powerbar,and give it a little extra so it doesn't come undone - hey presto....material limits exceeded.

My TLR200 has a high tensile alloy gearlever and it can't be straighted,but it doesn't distort around the shaft....it's a pretty good design.

[Ixion]

Cast iron ftw.

[Motu]

My mates old man used to own a non ferous foundry,and would get grumpy if he heard people talking about aluminium - ''There's no such thing as aluminium,it's all alloy!'' We could always make our bikes out of silver or gold,then they would be pure.....

[Grantasaurus]

I'm not completely inexperienced in practical matters, I do work on my own bikes and cars.
You learn a lot owning an Alfa. It was fun though, for all the pain it gave me.

Actually, there is a really good reason not to use aluminum alloys of any kind for components that get a lot of repetitive use, it has no endurance limit, unlike steel. What this means is that you can stress it as little as you like, but it will always fail and its just a matter of how many cycles.

[Motu]

Zigactly! hic.....

[Bonez]

Hacksaw a mill or two by the slot in the lever giving a slightly bigger gap. Tighten up the bolt. Being carefull not to overdo it and snap the lever.

[IronicCapers]

With the splines they make the lever the softer material so that your gear shaft splines arn't destroyed. Wat would you rather replace? But im just saying why cant another way be used to attach the lever to the shaft. And i mean why don't the manufacturers use it or will it cause them a decrease in aftermarket sales. As for why an aluminium one was used ios basically because they are the only ones available considering its an 1986 and they no longer make parts for it. Can i bitch sum more or have i reached the KB limit?

[IronicCapers]

Hacksaw a mill or two by the slot in the lever giving a slightly bigger gap. Tighten up the bolt. Being carefull not to overdo it and snap the lever.

Only works if yourve got a high tensile bolt. better idea is to file the inside of that particular area. another one is to build up the shaft but probably better to do the lever with weild and mak a tight fit.

[Mr. Peanut]

Yeah but the gear lever wears out then it starts flattening of the tips of the gear shaft :angry:

[Ixion]

Meh, just clamp a pair of vice grips round the shaft. Sorted.

[Bonez]

Meh, just clamp a pair of vice grips round the shaft. Sorted.That sounds very familiar :innocent:

[Bonez]

Yeah but the gear lever wears out then it starts flattening of the tips of the gear shaft :angry:Then you revert back to plan "A"- MIG.

[Mr. Peanut]

Then the heat travels down the gear shaft and all sorts of interesting things happen.

[Motu]

Nah,the MIG is very quick,puts a lot of heat in one place....and always have a slave handy to piss on it afterwards.....make that a male slave too....

[Mr. Peanut]

Nah,the MIG is very quick,puts a lot of heat in one place....and always have a slave handy to piss on it afterwards.....make that a male slave too....

I'll definitely consider it should it happen again.

[IronicCapers]

Meh, just clamp a pair of vice grips round the shaft. Sorted.

Dam u know wat i lik tht idea its almost kiwi but you forgot the number eight wire so you must be an immigrant. An id give u sum rep points but urve got a shite load so it dont really make a difference. hehe nice idea tho. To late got angry brought an AM gear lever