Tech Tips

TECH TIPS

Ever had a gearshift lever fall off or get so loose that it wiggled around on the shaft? Or was it a kickstart lever on a dirtbike that went missing during a trail ride? Levers sometimes even come loose not long after you’ve tightened the pinch bolt that holds them in place. That’s because when you tighten the bolt, the clamping force is not necessarily distributed evenly all around the shaft. A disproportionate amount of the force is placed on just the first couple of splines on either side of the split next to the pinch bolt, increasing the chance of the lever loosening over time.

There’s a simple way to reduce the probability of this happening again. Remove the lever and, with a small file or grinding wheel, cut away the entire first spline on both sides of the split. If your bike is an oldie with a lever that chronically loosens, you might even cut away the first two splines. When you reinstall the lever, the clamping force will be distributed more evenly around the shaft, making the lever much less likely to work loose.

Got a mechanical or technical problem with your beloved ride? Can’t seem to find workable solutions in your area? Or are you eager to learn about a certain aspect of motorcycle design and technology? Maybe we can help. If you think we can, either: 1) Mail a written inquiry, along with your full name, address and phone number, to Cycle World Service, 1499 Monrovia Ave., Newport Beach, CA 92663; 2) fax it to Paul Dean at 949/631-0651; 3) e-mail it to CW1Dean@aol.com; or 4) log onto www.cycleworld.com, click on the “Contact Us” button, select “CW Service” and enter your question. Don’t write a 10-page essay, but if you’re looking for help in solving a problem, do include enough information to permit a reasonable diagnosis. And please understand that due to the enormous volume of inquiries we receive, we cannot guarantee a reply to every question.