loose shifter

[Jeff Saline]

On Thu, 16 Oct 2008 16:23:49 -0000 "fasteddiecopeman" writes:

> Ever since shortly after my '04 was new, I find that the shifter > becomes loose on its splined > shaft. I've tried tightening it, but soon after it becomes loose > again, so I bought an "IMS" > shifter and installed it, tightened it down and figured I'd fixed > the problem. > > Nope! Loose again, so I removed the bolt and installed a longer one > so I could add a nut to it > at the bottom and tighten BOTH! Figured that HAD TO WORK. > > Nope, loose again. > > I'm not hard on my KLR, it's rarely off-road so not down for a LONG > time. Anyone else have > this problem? Got a solution? > > Thanks, > Ed

<><><><><><><><><> <><><><><><><><><> Ed, I'm guessing you've already checked this but... ...I'd probably inspect the shifter first when it was on the shaft and make sure it had a gap so the bolt can squeeze it together for decisive clamping action. Then I'd remove the shifter and clean the splines on the inside and also on the shaft. I'm not talking about a quick wipe with a rag but a really good cleaning with a stiff brush and solvent and maybe a scribe to clean each valley between the splines. If the gap was less than 1.5mm or about 1/16" I'd open it a bit with an abrasive wheel or disc. Then I'd make sure the threads were really good in the lever and also on the bolt. If the bolt wasn't a quality piece I'd replace it with something that won't stretch/break like the stock part. I'd clean them too. Finally I'd try to reinstall it and check for slop before I even put the bolt back in. Then the bolt would go in and I'd tighten it using a box wrench and also wiggle the shifter while tightening the bolt. I'd continue until it was either tight on the shaft or I pulled the threads off the bolt, snapped the bolt or pulled the threads out of the shifter. If you snap the bolt or pull the threads it'll be interesting getting the shifter off. Make sure you're at a shop when you do that. : ) I'm hoping this might be of some help but I'm betting you've already done this. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT ____________________________________________________________ Search competitive auto warranty quotes and get protection you can trust. http://thirdpartyoffers.juno.com/TGL2141/fc/Ioyw6i3nd2KItaTVcvCiJiOT4mjO01vLJzhZ0WARfr4TtqGc3QbTne/