Training Wheel Hero
Join Date: Sep 2006
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Limp gear shifter. What did I do ** Don't tap the Shifter Arm **
My bike has 24k kmhs on it now and the chain and sprockets are getting a little tired. Tonight I wanted to better inspect the front sprocket and in order to pull the front sprocket cover off I had to remove the shift linkage. I loosened the pinch bolt on the gearshift arm and even after removing the bolt completely the gear shift arm would still not budge so I resorted to a small puller, which did the trick nicely.
After inspecting the sprocket I started putting it all back together. Since the gearshift arm was stiff coming off it was stiff putting back on so I grabbed a small hammer and started tapping it on. As the gearshift arm (#1, see below) was half on I noticed the gearshift spindle (#3, see below) was now pushed about 1/2 inch further into the motor and the gear shifter was completely limp. I then pulled the gear shift spindle back out 1/2 an inch and the gear shifter felt 'normal' again, I then pushed it back in and it went limp again (just floats up and down, makes no contact with anything).
So now this gear shift spindle freely moves in and out of the motor 1/2 an inch where as it never did before. When its pushed in it spins freely, when its pulled out (normal) it shifts fine.
I did some research on line with shop manuals and put together what I think might be happening below. I suspect the Setting Plate (#2, see below) is either bent or broken, or possibly the bolt that holds it is gone. I have no idea though, just a guess.
Anyone seen this before? What the hell did I do!?