Shift lever fell off while down shifting.

Asad

Asad

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May 2, 2018
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Gear shift lever fell off today while riding home from work. Was getting off of an exit from rt101 at my home exit in Grover Beach and there was nothing to down shift with. Luckily I managed to keep shifting just had to turn my foot inward more to grab the lever by a ridge on my boot. I must say, this is not making me think “Hand Built at donington hall” is a good thing. Kind of disappointed to see something as simple as this just fall off. But oh well. I made it home alive. I drove back to the spot where it fell off but I couldn’t find it. So I spent a little bit of time making my own this morning. Made the lever out of an m6x45 bolt and two different gauges of aluminum pipes slid on to each other to make the finished lever thicker. Hoping to find a thick piece of rubber sleeve to finish it off. I put a small nut on the inside in hopes that it will stay on this time. Used red thread lock. Will let you know if this one falls off too.

Anyone else deal with this before and have a better solution?

Shift lever fell off while down shifting.


Shift lever fell off while down shifting.


Shift lever fell off while down shifting.
 
Nothing new, this has happened to others on this forum.
Of course, this should not happen, but the 961 does vibrate a bit, and this can cause the problem.
I can see that you loctited the motherf***er, good, now you can relax.:p
 
Don’t you do annual check ups?
That piece is very cheap.
I know I have some spares, if you like I could send you one.
 
Mine fell off day one on the 1st ride home from the dealer. Picked up one from the local Suzuki dealer and it was replaced at 1st service with a Norton one.
 
Good Idea using the lock nut too ! In fact that my be a good project for my bike , replace with slightly longer bolt and affix a locknut with a dab of loctite to the threads .
 
Voodooo said:
Don’t you do annual check ups?
That piece is very cheap.
I know I have some spares, if you like I could send you one.
Click to expand...

I've only had the bike for a 11 months so this was my annual check up. Will stay on top of it even more frequently from now on. If you have a spare and don't need it, I would love to have it. Here's my address: 1031 Newport Ave, Grover Beach 93433. If you're ever riding the CA coast you have a place to stop and have a nice glass of central coast Pinot Noir.
 
I'll add this one to the list to replace with castellated nuts or wired nuts/bolts. There are now some really nice titanium drilled nuts/bolts available at only marginally excessive prices.
After a long run I now always look to see what has worked its way loose before it drops off. Same as when I go jogging at my age.....
 
Eljahara said:
These bikes need more looking after than my kids did!
Click to expand...
"DID".You sound like you had a lucky escape. I changed my kids names to Norton and Harley. Both are expensive to run, and unlike my Bikes, I got rid of the kids years ago. It's like part exchanging your old bike and the dealer ringing up years later asking for money for repairs !!
 
I had to ride home like that once. Good thing there's enough space. I let a Harley rider try my bike. Hit the front brake and down he went. Only damage was that and a clutch lever. Glad he didn't break his hip.
 
Finished it off with plumbing pipe. Couldn't find black pipe in the exact size. Now it will match the upgraded spark plug wires. Attached with some grip glue.

Shift lever fell off while down shifting.


Shift lever fell off while down shifting.
 
Asad said:
Finished it off with plumbing pipe. Couldn't find black pipe in the exact size. Now it will match the upgraded spark plug wires. Attached with some grip glue.

Shift lever fell off while down shifting.


Shift lever fell off while down shifting.
Click to expand...
Hope that’s a temporary fix. Cause it looks it.
 
Britfan60 said:
I had to ride home like that once. Good thing there's enough space. I let a Harley rider try my bike. Hit the front brake and down he went. Only damage was that and a clutch lever. Glad he didn't break his hip.
Click to expand...
I would of broke his hip had that been my bike. Unless he was a elderly guy. Then I’d be looking at other problems :D
 
Took a couple of years before bits stopped falling off of mine. Had to get used to old school habits of checking things other than fuel and tyre pressures before going out for a blap. Frustrating at first but I have got to know my 961 better than my other rides and I feel beter for it. That reminds me, I have to check the engine oil in the boxer and blow the dust off the Honda.
 
Fast Eddie said:
I’m with the others who’ve said that whilst this is of course not good, this is an old skool machine that vibrates etc.
Fastenings DO NEED CHECKING.
Click to expand...
This is what memories are made of! Life can be a little dull if everything has to be perfect all the time. The old routine maintenance manuals always said you should check your nuts every 250 miles - that is your bike nuts....
 

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