Can't get gear lever off

[Kookas]

Undid the bolt but it just isn't going to come off that spline. Any trick to this? Cheers

It gets to the very edge and then after that the spline itself tries to move.

[qcbaker]

I would try and get a sturdy flat head screwdriver in between the part where the bolt screws in and clamps down, and rotate it slightly to open it up ever so slightly more to get over whatever is causing that to not come off. (most likely a little spur of metal on the end of the spline if the bike has ever been down/scraped on that side)

[Kookas]

Thanks, I tried it with a chisel but to no avail though.

[sledge]

You have taken the bolt out completely?

Backing it off isn't enough, it needs to be removed.

[the_63]

also try and take the lever off so that it is level, rather than wiggling it off.

[Kookas]

Thanks for the advice. Hammered a flathead driver in and got her off. Now just have to figure out how to break the old chain - haven't really got any power cutting tools like a dremel or grinder already. What's the best thing to buy just to get rid of this old chain?

[qcbaker]

Thanks for the advice. Hammered a flathead driver in and got her off. Now just have to figure out how to break the old chain - haven't really got any power cutting tools like a dremel or grinder already. What's the best thing to buy just to get rid of this old chain?

Does your chain not have a master link? you shouldn't have to destroy the chain to get it off...

[Watcher]

Some chains don't have master links if they're considered "continuous" or "endless".  I think the factory chain is like this.

I don't remember the swingarm arrangement but if you loosen the chain tension adjusters and push in the rear wheel there will be enough slack to just slip the chain off either end and pull it out.
If not and you don't want to go removing the swing arm, I'd add some tension to the chain to keep it taught and go at it with a hacksaw.
Or bolt cutters will work.
There's no real wrong way to remove an old chain.  If it's coming off its no good anyway so go ahead and destroy it.  Just don't destroy anything else in the process!

You may want a chain tool, though.  As always there is a right tool for the job.  If there is a cycle gear near you they have a chain tool kit for like $40 that works well.
It has a punch to press out a pin to "break" the old chain and remove it without destroying it (if you really want to keep it), clamps to press the new chain together and join it (not necessary for a master link chain but definitely makes it easier), and a riveter used to upset the pins on a new chain (again not necessary on a master link chain, but I did both the clip and upset the pins to make sure that clip doesn't accidentally come off).

[qcbaker]

Some chains don't have master links if they're considered "continuous" or "endless".  I think the factory chain is like this.

I don't remember the swingarm arrangement but if you loosen the chain tension adjusters and push in the rear wheel there will be enough slack to just slip the chain off either end and pull it out.
If not and you don't want to go removing the swing arm, I'd add some tension to the chain to keep it taught and go at it with a hacksaw.
Or bolt cutters will work.
There's no real wrong way to remove an old chain.  If it's coming off its no good anyway so go ahead and destroy it.  Just don't destroy anything else in the process!

That's true, I didn't think about endless chains. But OP, check this: http://wiki.gstwins.com/index.php?n=Maintenance.AdjustChainTension . This wiki article explains how to adjust the chain tension so you should be able to just loosen the tension until the chain can slip off. That way you dont have to cut through anything and risk damaging anything else.

[sledge]

The chain has to be broken to clear the swingarm pivot, either that or you remove the swingarm and part of the suspension linkage.

[Kookas]

Oh, yeah, forgot to mention I'm replacing both sprockets and chain, so I'll have to break the chain somehow. Already got the back wheel off and both sprockets replaced, just this chain is the final step.

[Janx101]

You can use a cold chisel and heavy hammer on a hard steel surface to just chop thru the link plates.   Its not exactly a finesse way to do the job and it's a bugger because the chain can rotate with impact. . But its a option!

[barry905]

+1 for the endless chain. At least mine was, and I ended up cutting it with a dremel (sure enough the swingarm gets in the way). In retrospect I should have got one of the chain tool thingies because the new chain I bought had to have some links removed - I couldn't find one locally that was the correct length. I've used one before and it makes the job soooooo much easier. Using a dremel is a pain.

[Watcher]

In retrospect I should have got one of the chain tool thingies because the new chain I bought had to have some links removed - I couldn't find one locally that was the correct length.

Very good point.  I don't remember if I had to do the same or not...

[Kookas]

In the end I picked up a proper tool and just pushed out a pin. Got the new chain on there but seems to be bogging down at 60mph now