$3 Motorcycle Shift Lever Repair

Leslie Kian a/k/a Bluepepper has provided the SV650 community with Shift Repair Instructions. We asked him if we could present his instructions here, and he agreed. His instructions are available below, and from this link. www.sv650.org (where we discovered Leslie’s instructions) is a great site for SV650 riders.

This procedure replaces the broken pin with a 5/16″ machine bolt, and reuses the rubber piece, which makes the installation look very professional. If the bolt breaks-off in a future incident, and you are carrying a spare, then you might even be able to do a roadside repair.

Here is a copy of the Leslie’s instructions.  The word “I” below, refers to Leslie Kian, who wrote these words.

A low speed slide brought my SV down hard enough on the pavement to break my shifter. It broke off at the “L” and I figured out a way to save it with some inexpensive hardware from a local store. Here is a picture of what it looked like:

Happy riding!

I drilled out the spot where the original was welded with a 5/16” drill bit. I used a punch to mark the center of the hole so that the drill bit doesn’t wander. I also widened the hole with a 3/8” drill bit, but only at a depth of less than approximately ¼” (you will see why next).

I purchased a stainless 5/16” machine bolt (figuring that this would be least likely to rust) with a tapered head and an acorn nut to match. The bolt fits into the drilled out hole and sits recessed in the hole because of the tapered head. The head is facing the bike and will not have any interference with other moving parts.

Taking the rubber off of the original and reinserted on the threads of the bolt, it is held in place with the acorn nut. The acorn nut is rounded, so I don’t think it would cause too much friction. Here is what the final product looks like:

It is saving me a few bucks (I found one on eBay for $35 plus shipping), but I also know I can do this on the road in a pinch where parts are not readily available for less than $3 and the use of a drill.

Hope this contribution helps a fellow SV rider. This website has made a positive impact on me and has enhanced my SV experience.