EuroKClub
General forum area => How To - Tech & Forum support => Topic started by: TomL on February 14, 2015, 04:27:26 pm
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Some information on how I rectified the floppy gear lever problem on my K1200S.
I got fed up with keep changing the rubbishy plastic BMW bushes.
This shows my solution on the left and the BMW set up on the right.
(http://i958.photobucket.com/albums/ae66/TomL_photo/CIMG6857_zpsabdba9d9.jpg) (http://s958.photobucket.com/user/TomL_photo/media/CIMG6857_zpsabdba9d9.jpg.html)
I bought a shoulder bolt and a length of brass tube which was cut to a few thou' less than the length of the unthreaded portion of the shoulder bolt.
(http://i958.photobucket.com/albums/ae66/TomL_photo/CIMG6860_zps82a40b10.jpg) (http://s958.photobucket.com/user/TomL_photo/media/CIMG6860_zps82a40b10.jpg.html)
The brass bush is bonded into the gear lever with a slight projection at the inside edge of the gear lever as shown
(http://i958.photobucket.com/albums/ae66/TomL_photo/CIMG6862_zps77b02a3a.jpg) (http://s958.photobucket.com/user/TomL_photo/media/CIMG6862_zps77b02a3a.jpg.html)
The bolt is thread locked into position.
(http://i958.photobucket.com/albums/ae66/TomL_photo/CIMG6866_zps97a2267f.jpg) (http://s958.photobucket.com/user/TomL_photo/media/CIMG6866_zps97a2267f.jpg.html)
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Nice mod that Tom might have to do it in the future.
bob
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Should mention that I bonded the bush into the lever with Loctite 638. All the parts were sourced on ebay and came to about £12. The brass tube is long enough to make about 10 bushes and needed a bit of fettling with emery to fit the shoulder bolt nicely.
(http://i958.photobucket.com/albums/ae66/TomL_photo/CIMG6865_zps56d96766.jpg) (http://s958.photobucket.com/user/TomL_photo/media/CIMG6865_zps56d96766.jpg.html)
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Did you keep a record of the bolt you bought Tom?
The one thing I don't like about the Koenigsberger kit
http://www.kberger.net/product.php?product_id=14&back_cat=6
I fitted is that it keeps the original bolt and I hate the thought of threads acting as a bearing surface.
Brian (who thinks Tom could make a tidy profit selling the bits as kits 8) )
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It is an M8 x 10 x 20 high tensile shoulder bolt. Could have made up some kits but there didn't seem to be much interest.
http://www.ebay.co.uk/itm/Socket-Shoulder-Bolts-High-Tensile-12-9-Socket-Allen-Key-M5-M6-M8-M10-HT-/271319010373?pt=UK_DIY_Material_Nails_Fixing_MJ&var=&hash=item3f2bdf8c45
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What size was the brass tube Tom?
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I figured you were going to have to get the bush machined and the cost of that would have made a kit unreasonably costly seeing as I already have the Konigs thingy kit. For a piece of brass cut to length and the correct shoulder bolt, I would have been happy to pay.
Can I ask how much side to side play you have with this set up?
Brian (who wonders why BM think it acceptable to put plastic top hats in there original levers)
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I am lucky enough to have a Chester Conquest mini lathe, so the turning should be a doddle.
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The brass tube was 14mm outside diameter and 10mm bore. A lathe would have been ideal but I had to make do with a hacksaw and file. I fettled the brass bush to achieve .02mm side play.
This is the tube that I got off ebay.
http://www.ebay.co.uk/itm/Large-diameter-seamless-metric-brass-tube-with-a-range-of-wall-thicknesses-/161592345877?pt=LH_DefaultDomain_3&var=460590625705&hash=item259fa78515
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Thanks Tom I might give it a go.
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Looks good Rae. If the brass bush is the correct length, (a few thou shorter than the shoulder section of the bolt), then you shouldn't need a washer on the bolt. ;)
I see that you did yours on the carpet in the lounge like what I did. :-[
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Hi Tom,
Saw this and really like it, couple of quick questions:
When you say a few thou (not really a user of old money) shorter than the threaded section, did you just go by eye or did you have a measurement?
You mention bonding the brass tube in to the shift lever... any reason for that? I would have thought it wouldn't matter if it was free and just slotted into the hole in the lever?
You also mentioned 'fettling' the brass tube to achieve some side play. Presuming you just used some emery cloth or similar to 'sand' it down a bit?... also I never really got the 'side play' business, I know it's supposed to be there but do you know what the benefit is?
Many thanks... and appreciate it's a few years since you posted this.
Cheers
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I’m interested in this. My floppy gear lever is crazy.
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The answer is a K13S. This is one of the things they most definitely did fix from the K12S...
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I think I have the parts somewhere that I never got around to fitting to my GT
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Hi Tom,
Saw this and really like it, couple of quick questions:
When you say a few thou (not really a user of old money) shorter than the threaded section, did you just go by eye or did you have a measurement?
You mention bonding the brass tube in to the shift lever... any reason for that? I would have thought it wouldn't matter if it was free and just slotted into the hole in the lever?
You also mentioned 'fettling' the brass tube to achieve some side play. Presuming you just used some emery cloth or similar to 'sand' it down a bit?... also I never really got the 'side play' business, I know it's supposed to be there but do you know what the benefit is?
Many thanks... and appreciate it's a few years since you posted this.
Cheers
I did say, a few thou' less than the length of the UNTHREADED portion of the shoulder bolt. If it is too long then the bolt will grip it and it will not rotate. I bonded it into the lever so that the brass bush would rotate on the bolt rather than the aluminium lever rotating on the brass bush. If there is no side play (axial movement) it wouldn't operate.
Hope that makes sense to you now.
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Cheers Tom, many thanks for your help.
That's great... and of course makes perfect sense when I re-read... if the bush is longer than the un-threaded section it'll just be clamped in place.
The one bit i'm not completely clear on is how you 'fettled' to give the side play? Did you just grind out the bore a little or or something completely different?
Cheers
Gary
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Cheers Tom, many thanks for your help.
That's great... and of course makes perfect sense when I re-read... if the bush is longer than the un-threaded section it'll just be clamped in place.
The one bit i'm not completely clear on is how you 'fettled' to give the side play? Did you just grind out the bore a little or or something completely different?
Cheers
Gary
Before you bond the brass bush into the lever bolt it into position with the new shouldered bolt and make sure that the brass bush is able to rotate on the bolt. With the bush bonded into the lever it might be necessary to file a bit off the lever at the bush end if it fouls on the casing preventing any side play.
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Old post but need help.
manage to outsource the bolt but cannot find the brass pipe anywhere.
14x 10 inner diameter is nowhere to be find ??
Anyone can help to find it?
thanks
Alain
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Surely eBay must have something - seriously, they have everything 8)
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the only one i finds in 14 mm got a wall thickness of 1 mm making the inside diameter of 12 mm.
Need a inside diameter of 10mm according to the original post.
but the search still on :D
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How long is the brass tubing roughly? I have a length in my van.
Send me a pm with your address and I will post it to you. You will have to file it down to the correct length.
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I applaud your generosity... 8)
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Thank you Tom for sending the copper tube so quickly . :) :)
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You're welcome.
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He's a thoroughly good sort is Tom :)
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Do we know the correct length for these bushes? I did mine years ago, on my old bike. Not had to do it on the new bike yet, but the time will surely come...!
If we can figure out the length, I think we have all the necessary dimensions to mass produce them on a lathe.
Steve
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The 13 gear lever was redesigned if I remember correctly.
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Typical! Something small like a gear lever, they fix. Clutch? Nah, we did enough work on that already!
Fair enough. The offer is still there though - if someone can tell me the correct length, I’ll be happy to make a few of them for folks that are in need, as long as they cover postage and the cost of half a pint!
Steve
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Half a pint? You're so cheap ;D ;)
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...he does drink scotch though ;D
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Well spotted Brian - I never said what I drink!!
(a half of mild will be fine!)
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Well Steve you know how to live it up :o ;D
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Bump....