Gear linkage loose

Over the years the lever is loose on the stud lever pivot. I don't want to buy a whole new lever, anyone any ideas what kind of internal sleeve to use?

I had this on an old Honda once. I filed the slot open a bit wider,so that when the pinch bolt is tightened down,it has a better grip. More pinch.
Its still working today.

If you replace the stud that will remove some of the slop. As for what type of sleeve, bronze is commonly used for sleeves. Sleeving that shifter would be difficult unless you are a machinist and have access to the proper equipment. A reamer of the proper size would be needed for one thing.

I've used a thin gauge slice of aluminium which has worked to an extent, still a bit loose. I'm sure i can get a suitable thin piece of bronze

davido wrote: I had this on an old Honda once. I filed the slot open a bit wider,so that when the pinch bolt is tightened down,it has a better grip. More pinch.
Its still working today.

In regard to davido's comment, I don't see how that would apply in the case of this shift lever.

The lever has a bore that slips over a stud mounted to the case. The lever is held to the stud with a C-clip. There is nothing to "pinch".

Regarding sliding an aluminum shim inside the lever to tighten up the fit, all I can say is good luck. There are various ways to fix broken bike parts, but that sounds like the wrong way.

It sounds like any solution would be a stop-gap or bandage until a real option could be purchased - new parts to replace the worn ones.

Are replacement parts available?

Could the receiver & shaft be cross drilled for a spring pin of sorts?
Just another bandage but may buy some time until replacements are acquired...

A bronze bushing would be a good choice , but it will require careful machining of the shifter and the shaft to insure a good fit. A small zerk for grade would be good for the long run. The sexiest solution would be needle bearings. A member of the ZRXOA does a bearing conversion for the ZRX. Maybe he would be willing to do a KZ, too. If you are interested, I can chase down his contact info when I get home tomorrow night.

Cheers Texas but I'm in the UK. I was looking at a replacement lever link but you can't seem to get a new one. There are a few used ones on ebay but these look pretty worn. A bearing solution would be ideal. Another solution would be to do away with linkage and use a normal shift lever but that would take the end of the lever too far forward. I've got big feet but not that big.

Thinking about this a little more and I think the easiest thing to do would be to install a sleeve around the old stud. A machinist could easily turn down the old stud a little in a lathe and then press a bushing onto it. If you want a truly righteous fit I'd ream out the ID of the shifter bore with a reamer to the next larger size and size the bushing so you have a nice tight fit.

Great idea, friend of mine has a lathe and could do this for me, cheers buddy

Nessism wrote: In regard to davido's comment, I don't see how that would apply in the case of this shift lever.

The lever has a bore that slips over a stud mounted to the case. The lever is held to the stud with a C-clip. There is nothing to "pinch".

Regarding sliding an aluminum shim inside the lever to tighten up the fit, all I can say is good luck. There are various ways to fix broken bike parts, but that sounds like the wrong way.

My mistake. A different system to the one I was thinking (writing) about.