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 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
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.....