Gear Lever Bodge

[squirrel_hunter]

Thought some of you out there may be interested in my latest bodge job...

Coming back from the MoFo meet last night when I got to my garage I decided that I would try and get off the bike and open the door without putting the side stand down properly first. Needless to say bike and rider ended up in a heap on the floor. Unfortunately I couldn't even drop the bike properly as I had no audience to point and laugh at me. So damage wise cracked some more of the front panel, snapped the end off the clutch leaver and bent the gear change leaver (not that anyone could actually spot the damage).

The gear leaver was bent in which had also bent the linkage rod. It was still ridable but changing up was like doing yoga, so I attempted a bodge. And here is the results.

From this:




To this:




There is a small prize for guessing what bike the donor leaver is from, as a clue its a Honda...

Its not a perfect fit as the SV leaver is thicker at the peg but theres no movement in it when riding. The biggest problem was the linkage rod with the reversed thread. The Honda engine side has the reverse and the leaver the correct way, the SV is the opposite so I didn't have a rod that could fit and the Honda engine side mount is to small for the SV's output shaft. So a quick trip to Wicks and for 80p I bought some threaded rod and made my own. Little bit of adjustment and I had it at the right height.

So the old leaver will go off to be straightened (again) and then go back on. Overall a successful and cheap bodge job thats keeping me on the road.

Originally Posted by squirrel_hunter

I decided that I would try and get off the bike and open the door without putting the side stand down properly first

Proper job

[Kylie]

Did a similar mod on my pointy, don't know what bike the new part came from (got it from a friendly mechanic) but the one that bust was a casting while the donor part looks like it is forged. Anyhows the new one is way better, I have dropped the bike since and it just bent, simply bends back by hand. Don't ever want the OE part back!

Cbr400rr Nc23/?!

Youve never fitted a C90 clunker gear change have you?

That is a shamefully dirty SV

Good job, well done.

A good friend of mine taught me to think outside the box when it came to repairs and it has come in handy a few times when coming across a problem that needed fixing on the SV.

[squirrel_hunter]

Originally Posted by gettin2dizzy

Cbr400rr Nc23/?!

Congratulations you win!

Yep striped it off the project bike, it was really a take it apart and see if it fits no real planning involved

Originally Posted by Torn-Thorax

That is a shamefully dirty SV

Thats not shamefully dirty, everyone knows that the fastest bikes are the dirtiest.

heh heh, reminds me of last summer.... my bike fell off the sidestand at 3am on a roadside in Andorra..pointing downhill...doh.

Exact same damage..snapped gear change lever peg and clutch lever end.

Managed to bodge the gear change lever back together with a thick allen key from the tool set, and some insulating tape one of the other lads had.

Had to buy a new gear lever in barcelona the next day for 70 euro..was gonna wait and get one on ebay, but glad i didnt because......

Bought a new tyre in andorra on the way back 2 days later, going around a french roundabout at a petrol station I had a bit of a slip and wobbled myself wide onto grass, bike fell over, threw me off, and snapped my rear brake lever.....

The remains of my gear change lever/allen key/tape fitted nicely onto what was left of my brake lever and got me back home 2k kms

Moral of the story..always carry allen keys and duct tape/insulating tape.

EDIT: got hit by a bus at low speed a week later and broke all pegs and levers......... Doh.

Originally Posted by squirrel_hunter

Thats not shamefully dirty, everyone knows that the fastest bikes are the dirtiest.

High Speed Dirt (megadeth song)


Seriously, its really dirty

But then perhaps we're all too used to kwaks bike...

Matt