You may have working levers but the fact remains the smaller shaft (compared with Triumph's) with the channel down the middle for the pinchbolt leaves the bare minimum of shaft-lever contact area. It's not good design, given the amount of repeated stress this part sees, especially if the bike is, like mine, ridden daily.
What are you talking about when you say "bare minimum of contact area" its EXACTLY the same amount of contact area as the Triumph type !! :-D
Fact is the shafts probably had 40 plus years of use & now getting "used daily" & that's your idea of a bad design ?
Ive had this type of lever on bikes since the 1970's if they are never used with detectable play at the joint they last a good long time. BSA saw no reason not to fit them on the triples also.
The BSA type deters people persevering with worn out parts whereas the triumph type allows prelonged use of the worn out parts.
There's a worrying trend here for deciding to redesign things that in original form may well have lasted 10 or 20yrs from new.
You're right, of course. I'm just frustrated at the damage that has been done by a previous owner and mis-placing the blame.
Anyway, this is what I have to work with, including worn splines, and a cotter bolt hole drilled at an angle! (that bolt's only in there to demonstrate the angle of the drilling.
And this is what I am hoping may be enough of a solution to get me the 90 miles home. The lower lever is the replacement piece I bought. The upper, with real *manly* splines, I am hoping will get enough of a bite on what remains of the shaft's splines to get me back. Only thing is it doglegs out to go round a much wider engine casing and the toe area is offset about 2.5". But hopefully it will get me and the bike back to the shop to replace the shaft.
I'm also going to buy a small vice grip and stick it in my back pocket. Worse case scenario that can be enough of a shifter lever to limp home.
Ok so now lets look at a suitable bodge, if I was in your shoes & wanted it to work but will be replacing shaft & lever in the near future I would simply mig weld a blob on the end fusing the correctly placed lever to the shaft.
That can easily be ground off & rewelded whenever you want the lever off, until new parts are sourced.
Yes I am aware of that bodge. Discussed it with the guy who owns the shop I use (6th St Specials around the corner from me). Unfortunately the bike is 90 miles away, and I don't possess a welder, so I am hoping that upper lever in the photo will provide enough grip to get the bike back to the city.
However, were I to borrow a welder, I should grind off the plating on the lever where I am going to weld the blob, correct?
Now if you are just trying to do some thing to get you home and you are going to replace the gearshaft shaft. 1) pop a pair of small vice grip pliers on there and be gentle with the gear changes. I have done this several times when on a ride with the club when some ones gear change lever falls off about ones every year or two.
2) put the lever on loosly then tap some very thin panel pins between the shaft & the lever before you tighten it up. panel pins are the tiny nails that used to be in backs panels of furnature before staples were used.
3) Good old coke cans, Open the lever out a bit further by jamming a screwdriver into the slot. Cut a coke can ( beer cans work better ) shim to go around the shaft. slip the lever on, pull out the screw driver and tighten the bolt.
4) liquid metal. Unlike the top 3 this one I have never seen in use but others swear it does work. Similar to the coke can shim. Spread the lever, coat the shaft with liquid metal, put the lever on. GO have a beer ( or 3 ) while the filler hardens the pull out the screwdriver and tighten the pinch bolt.
Well I did mention vice grips/pliers a few posts back, its an extremely good get you home fix, we used to call them Mole Grips aswell but what ever you want to call them,the curved jaw ones do a good job.
I just got a 68 Victor and it has the problem with the shifter as y'all mentioned. It would appear to me the problem is the hole's a bit too big on the shifter and the metal a bit too hard to compress. What if one made the slit longer on the shifter so the pinchbolt would have a easier time of compressin it? Or my other idea is to cut the shifter lever forward of the bottom to the slit therefore allowin the piece to compress to the shaft? I've got 2 shift levers, neither fit so I'm up to tryin somethin as vicegrips won't compress mine enough to work. Gene