Ok really struggling for any info on how to change the gear shaft lever. I have a new one on it's way and have no idea where to start. Current one is slightly bent so needs to be done.

Anyone clued up on this side of things?

if im on the same page as you.... your talking about the little foot control that switches through the gears right?

if so there is only one screw holding it on, all you have to do is take it out and use a screw driver to gently pry it of.
there are teeth kinda like the rear sprocket holding it in place so you cant spin it, but if you use even pressure on top and bottom you can pop it of.

Or do you mean the had clutch lever? If so, watch this:

http://www.youtube.com/watch?v=1-yM57FL99U

Sorry should of explained better you are both off.


Where the gear lever is on your foot, the long shaft that the lever is attached to, to switch gears, goes inside the engine. I need to replace that.

damn never did that one... sorry man, cant help you there lol
but im sure our local parts whore got it coverd, or when in doubt ask THE ALMIGHTY BUDDAHA LOL

Never did that. Probably have to split the case to remove the transmission.
Why do you think you need to replace that? Pretty rare to ever have to replace that.

wow i was wrong... does the part whore at least have a replacement in stock?

Quote from: NorwayGT1 on November 15, 2011, 11:54:26 AM
wow i was wrong... does the part whore at least have a replacement in stock?

Not this whore. East coast parts whores? Anyone?

well im officially shocked! lol try sending a pm to buddaha he might have a clue

There is no need to split the cases and it can all be done with the engine in situ

Both covers off.
Clutch and basket off.
Couple of bolts and springs and the selecter linkage comes off the drum.
Circlip holding the shaft to the linkage comes off.
Shaft will pull through from the clutch side, think there is a couple of spacers and a spring on the shaft.

When you see the mechanism it will all make sense.

Haha got me worried there no way i'm removing any engines! I found a replacement one on ebay so all good.

Sledge would you say this can be attempted by someone who is using this bike as their first mechanical DIY toy? Just don't want to mess anything up while i'm in there. Managed to basically rebuild the clutch on my own so i'm not too nubby at this sort of stuff.

If you have had the clutch off this is no harder than that. As sledge said, once the clutch is off (you also have to remove the basket which you may not have done before, will require large socket and long handle) you disconnect the shift linkage from the drum and shaft and the shaft slides out (clean the sprocket end of it thoroughly and consider replacing the seal while you're there).

Pretty much everything that was said above. I'd recommend snapping some photos of the gear selecter mechanism while you're under the clutch cover... It'll reduce your frustration trying to get everything back together once you're done.

If you've removed the clutch hub before, this is pretty simple. If the rear wheel is on the bike you just need a 37mm socket to get the nut off. Hold it in place by putting the bike into gear and locking the rear brake. If you need to hold the outer gear, a penny between it and the crank will work fine.

The job isn't super complex. The normal stuff regarding removing an engine cover applies.

Thanks mole and burning really appreciate it, will take a stab at it when i got some free time!

Cheers guys!

Hi guys. Hopefully a quick response as working on the bike at this minute! I've removed the linkage but the shaft won't pull through. It's stuck solid. I've lightly tapped the sprocket cover side with a hammer, it moved a little and now it wont budge at all! Heres a pic, can someone check i've disconnected everything properly?

http://imageshack.us/g/822/dscf0433pw.jpg/

Ok i've managed to start pushing it through, by use of force with a hammer. It's pushed through quite a bit, although it is still sticking out of the front sprocket cover side. It wont budge anymore at all. I fear its far too bent to just slide out?? Clues??

Ok sorted the problem. Ended up sawing off the gear shaft at the clutch end, to get rid of the linking then pushing it out through the sprocket cover end.. worked a charm!

You must have had a huge amount of built up gunk on the lever. I just had to wipe off the sprocket side end, and push it through with my fingers.

Always wary about beating on engine parts with a hammer. It's got to be done sometimes, but... Check and double check, and triple check is my motto. Unbelievable how often it's being held in place by something I missed.

Hi burning1 thats what i though but i realised i had removed everything properly, just the gear shaft was to severely bent to pass through the tunnel straight so some DIY had to be done, worked a charm though amazingly.

I have sent you a pm regarding another problem as to forgetting how the linkage goes back on, not sure if my PMS are working though?

Let me know, thanks.

I did see your PM. Fortunately, I took my own advice and snapped a few photos with my cell phone. I started a new thread so that the info would be readily available in case anyone else needs it (probable.)

http://gstwins.com/gsboard/index.php?topic=58411.0