Having trouble replacing my gear shift foot lever - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
DL650 and DL650A - 2004 to 2011 DL650 from 2004-2006 (K4-K6) and DL650 or DL650A from 2007-2011 (K7-L1)

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post #1 of 16 Old 07-07-2019, 04:04 PM Thread Starter
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Having trouble replacing my gear shift foot lever

I’m not all that mechanical to be honest, so please take it easy on me as I know I’m making this job harder than it needs to be.

Broke my shift lever and just got the replacement part in yesterday, but can’t seems to figure out how to get the old one off. It’s not a traditional nut like my dirt bikes I’ve replaced, so am having trouble. I don’t want to ruin this seal but am not sure how to get it off without tearing it to pieces. Could somebody tell me how stupid I am and how this seal comes off so I can put the new lever on?

Thanks in advance and I apologize for my stupid question. Pic attached below.
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post #2 of 16 Old 07-07-2019, 04:13 PM
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Looks to me like its held on with a snap ring. It's that little horseshoe shaped clip with the two holes at each end. If you have snap ring pliers you spread the ring apart and slip it over the end of the shaft. It can be removed without snap ring pliers but you run the risk if it being flung across the room and getting lost.
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post #3 of 16 Old 07-08-2019, 04:20 AM
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From the part diagram, https://www.mrcycles.com/oemparts/a/.../gear-shifting, you can have a clearer view of how the gear shift parts are assembled / fitted together.
A sir-clip / snap ring pliers makes life so much easier in working with the clip. Just remember when using the pilers, open the clip wide enough to slide it off the perch. Do not use excessive force when opening the clip or you could easily deform it so that it will not clamp again. Press the gearshift lever in towards the bike, to give a bit of clearance.
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post #4 of 16 Old 07-08-2019, 04:34 AM
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What you really need is a pair of snap ring pliers. Fine screwdrivers and needle nose pliers might work, but as gdrew says, it may end up being flung anywhere. The snap ring sits in a groove in the shifter shaft, preventing the lever from sliding off.
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post #5 of 16 Old 07-08-2019, 05:02 AM
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https://www.harborfreight.com/snap-r...ads-63845.html

Or post up your location, maybe you are near another inmate that can ride by and give you a hand.
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post #6 of 16 Old 07-08-2019, 04:19 PM
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Don't damage the snap ring by over stretching it. The ring should be perfectly flat after you remove it. Remove carefully, holding you finger over it so it doesn't go flying. Clean the groove, & grease the pivot shaft.

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post #7 of 16 Old 07-08-2019, 04:58 PM
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THIS is why this is a great forum. People here genuinely want to help.
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post #8 of 16 Old 07-08-2019, 05:36 PM
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And remember that snap ring is the same color as asphalt. If you drop it on pavement you will need a rolling magnet to find it.

These instructions may help. They show how to remove the gear shift and all those cautions above about not overstretching the ring are right on the money.

https://www.adventuretech.biz/gear-s...tructions.html
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post #9 of 16 Old 07-08-2019, 07:14 PM
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Start collecting tools.

I would start by reviewing the links others have provided to determine if you think this is a job you feel confident in taking on. It really is straightforward, and you shouldn't have any insurmountable problems. Next, A trip to your local hardware store, big box home improvement auto or tool section, or an auto parts store for a pair of snap ring pliers (also called circlip or retaining ring) similar to the ones that @Brockie pictured. Amazon has them starting around $8US & up. Removal and re-installing the clips is so much easier with the right tool. You may eventually want to dive into wheel and steering stem bearings and they also commonly have this type of retainer.

Today snap-ring pliers. Tomorrow...
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post #10 of 16 Old 07-08-2019, 07:17 PM
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Quote:
Originally Posted by Motorpsychology View Post
I would start by reviewing the links others have provided to determine if you think this is a job you feel confident in taking on. It really is straightforward, and you shouldn't have any insurmountable problems. Next, A trip to your local hardware store, big box home improvement auto or tool section, or an auto parts store for a pair of snap ring pliers (also called circlip or retaining ring) similar to the ones that @Brockie pictured. Amazon has them starting around $8US & up. Removal and re-installing the clips is so much easier with the right tool. You may eventually want to dive into wheel and steering stem bearings and they also commonly have this type of retainer.

Today snap-ring pliers. Tomorrow...
...
I see no problem with this

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