Gear shifter fell off - make sure it's tight - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 15 Old 06-24-2005, 11:05 AM Thread Starter
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Gear shifter fell off - make sure it's tight

FYI When commuting to work today, I started to down shift to stop and low and behold, my gear shifter fell off! It remained dangling on the bike with the brake light adjuster. When I pulled over to investigate, I found that the bolt portion that attaches to the foot peg bracket had come lose and fell off. I was able to get it back on and re-tighten.

I just wanted to give everyone a heads up to make sure that this bolt is checked for tightness, so that this unpleasant event does not happen to you. Im putting this bolt tightening routine into my maintenance procedures. You don't see the bolt when looking straight at the shifter because it is on the backside of the shifter. You have to literally get underneath the bike to see the thin both that allows you to tighten the threads. A wrench thin enough to fit between the foot peg bracket and the shifter is required. I still have to tighten mine when I get home, because the tool kit wrench is to fat, and does not allow you to tighten completely. I tightened as far as I could with the wrench, but then had to use the cheap pliers that came with the kit because the nose on them was thin enough to get the bolt hand tight.

There was no warning signs, as the bike was shifting fine before it happened. Bike is a lovely blue DL1000K5 (fastest color, when shifter is attached!)

Lencho - Blue DL1000K5

A former Motocrosser living in a middle aged, creaking body
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post #2 of 15 Old 06-24-2005, 12:17 PM
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No worries on mine. I tried to take it off the spline once to lower it but it wouldn't budge.

06 DL-650 - SilverBlue
05 DL-650 - red (RIP - watch your mirrors!)
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post #3 of 15 Old 06-24-2005, 12:22 PM Thread Starter
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This has nothing to do with the spline attachment. That piece of the puzzle was fine and intact!

Lencho - Blue DL1000K5

A former Motocrosser living in a middle aged, creaking body
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post #4 of 15 Old 06-24-2005, 02:18 PM
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You're talking about the actual piece that attaches to the tranny, I suppose. I'll give that a look, then.

06 DL-650 - SilverBlue
05 DL-650 - red (RIP - watch your mirrors!)
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post #5 of 15 Old 06-24-2005, 02:22 PM
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Mine fell off too. What you need to do is remove the clip and shifter to get to the bolt. My son was riding when it happened. He rode about a mile home. The end lever was bent in a little bit. I'm happy that it didn't break it.
Make sure you put some loctite on there when you tighten it back down.

Tom, it's the pivot bolt on the frame, not the linkage or shifter shaft.

'05 DL1000
'02 ACE 750
'03 TTR225
'79 IT175
'76 RD200
'75 TS75
'74 DT175
'73 G3SS90
'72 MC400 "Square Barrel"
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post #6 of 15 Old 06-24-2005, 02:39 PM Thread Starter
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Thanks Dan. Sounds like the way to go to get this bolt tightened properly. I'll take the clip off, remove the shifter to get to the bolt properly. Loctite on the treads and hunker down the bolt and I should be set.

My shifter bent a bit on the base too, where the brake light attches. Hopefully, it will straighten up a bit for me without breaking.

Lencho - Blue DL1000K5

A former Motocrosser living in a middle aged, creaking body
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post #7 of 15 Old 06-24-2005, 03:10 PM
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Make sure you use a finely calibrated elbow torque wrench when you tighten it. That was my biggest concern. Stripping the bugger. A good oomph ought to do ya. I think it's 15mm. Be careful trying to bend the lever. I think it's some kind of an alloy, ie: brittle! I was trying to bend my lever back until that thought struck. I suppose one or two perfectly timed bounces off the street will bend it but not a hammer/lever. The good news was I raised it some while I had it apart. Much better for boots.

It would be nice to have a folding lever. I wonder if anyone makes one?

'05 DL1000
'02 ACE 750
'03 TTR225
'79 IT175
'76 RD200
'75 TS75
'74 DT175
'73 G3SS90
'72 MC400 "Square Barrel"
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post #8 of 15 Old 06-24-2005, 04:10 PM Thread Starter
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I already straighten my brake lever once (dang mud and TrailWings don't mix well), so hopefully the shifter will cooperate too.

I saw a nice folding lever here:

http://www.touratech-usa.com/shop/ho...03761CF3DC7070

A bit pricey at $40, but nice none the less.

Lencho - Blue DL1000K5

A former Motocrosser living in a middle aged, creaking body
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post #9 of 15 Old 06-27-2005, 12:27 PM
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Quote:
Originally Posted by dan-c
Tom, it's the pivot bolt on the frame, not the linkage or shifter shaft.
Yeah. I finally took a look at my shifter and figured out what was going on. The bits and pieces get jumbled up in my head unless I'm actually looking at the bike or a diagram. Looks like I'll finally get to use the snap-ring pliers I picked out of the $4 box at Tractor Supply. :!:

Anyone know, offhand, what the proper torque is?

06 DL-650 - SilverBlue
05 DL-650 - red (RIP - watch your mirrors!)
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post #10 of 15 Old 06-28-2005, 11:07 AM
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The bad news is that the $4 pliers worked like $4 pliers. The good news is that the bolt was nice and tight.

06 DL-650 - SilverBlue
05 DL-650 - red (RIP - watch your mirrors!)
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