Katana Owners Club U.K.

Please don't tell me I have to buy the whole lot, including the pedal!

The plastic balljoints on the ends of the adjustable rod are just about shot, and look like they are about to pop, thus giving a very crap gearchange.

Is there a fix? Or is it going to be a whole new assembly?

J

i bought the lot off ebay a few months ago for a tenner i think it was + post... ended up not needing it as i found mine again!.... it's missing the rubber boots and the left hand locking nut from memory but if you want it for what i paid for it then you're welcome t it. can send you a pic if it helps :-/

by the "lot" i mean the lever, the shaft and the splined bit

Steve,

Having examined ours a bit closer, it would appear that the balljoints arent that bad - The excessive wear is in the pins where the balljoints are riveted on to the shift pedal and the spliney bit, making over an inch of pedal travel before you get the clunk.

Missus suffers with her left foot, and clunky she can do, the problem is the upward movement for upshifts.

I'll willingly take yours off your hands if it's any better.

Send me a paypal invoice to jrh@g0fhm.co.uk and I'll get the beans off to you.

Cheers,

J

i'll need to dig it out of... somewhere. what i'll do is send it to you then if you're happy with it you can sort it out.... that way if it's no better than yours simply send it back and there's no need to keep it. let me have your address and i'll get it send to ya.... when i find it. shouldnt be too hard.... hopefully!

if its loose on the pedal because the pin as worked loose where its peened over then you can put it in a vice and set about it with a ball pein hammer to take out the slack.

Right ho...

I have a replacement linkage here courtesy of sparki.

The final issue I have to overcome is on the end of the selector rod.

The splines on the end have been severely mullered (looks like somebody has had mole grips on there shifting the gears). With the old linkage, no matter how tight I wrenched up the pinch bolt, it wouldn't pinch enough to grip, and there was movement (enough to translate to a fair bit at the pedal).

Obviously the gearchange rod needs to be padded out at the splined end, but any suggestions how?

I could replace the gearchange rod I suppose, but it's more expense - And I havent got a puller to get the clutch drum off.

Any suggestions?

Cheers,

J

shouldnt need a puller to remove the clutch drum... on the bigger motors they're removable by threading in i think a 6mm bolt to just push it off. isn't like eg: removing the alternator.... but there again those are 16v motors and this one isn't :-/ - dunno. maybe someone has a replacement rod lying around. i've got one in a spare motor but thats complete besides the wan$^%$d head on it. push came to shove i could remove that one but at a last resort bud

I'll try a little engineering trick first.....

I have some Belzona sausage kicking around here somewhere (like chemical metal, but industrial strength), and will try building the end of the shaft up with that and rounding it off, and hopefully it will key into the duff splines and the splines on the female end of the linkage will bite into it when the pinch bolt is tightened. That's theoretically possible!

I used that to fix a broken exhaust hanger/rear footpeg bracket on my Triumph a couple of years ago - didn't look pretty but it worked till I could get a new one! Half the factory I used to work at was held together with that stuff.... If you had a knackered thread and not enough surrounding metal to drill and put an insert in, then you could fill the hole with that stuff and then drill and re tap. Awesome stuff!

J

So thats basically bodging it then ...........Why dont u just do the job properly, whip the casing off and replace the gear change shaft!