Triumphrat

dunringil · 08-07-2005, 12:57 PM

The gearshift shaft broke on my adventurer.

The shaft is knurled and has an undercut in the middle of the knurls, looks like it was designed to break there so it doesn't do internal damage.

Anyway, how hard is it to replace that shaft, or should I consider getting it welded?

I have another one, from my parts bike.

Looks like there is enough left to reattach, i might do that just so that I can ride it to the shop.

Slinky · 08-07-2005, 01:42 PM

I think you have to split the crankcase to do it properly. This is a common problem for bikes which have been dropped on the left.

An easier way is to drill and tap the shaft, and join the two parts with a bolt.

maxpower · 08-07-2005, 06:16 PM

You have appeared to have stumbled on common problem.

Broken shifter shaft

shift shaft solution

Search Hinckley Classics forum for Shifter for more

ClassiclyMobile · 08-08-2005, 02:12 AM

I broke mine and asked the dealer if he could replace it without splitting the cases. He said a mechanic that used to work there had done it and he would try. It took him over 4 hours to do it but said that now that he knows how it should take about two and a half hours labor.
CM

TexasTri · 08-08-2005, 01:23 PM

I had the same problem, but since the shaft broke in the indentation I decided to see if it could be welded. First thing I did was use a dremel tool to cut a slot in both the shaft and the tip that had broked. Then I cut a short piece of metal to fit in the slot. Kind of like a wooden biscuit in carpentry.

I took it to a welder and he made a small jig to put over the shaft so he could hold them in place and weld a section, rotate the gig and weld a little more.

Cost me $100 for the welding and is just like new. The other two options of splitting the cases or going through the sump were not what I wanted to do.

If you decide to do this there are some on the forum who have done it and can show you pics of the small tool required for going through the sump. I know as I got the advice when I was considering my options.

Good Luck.

parrycm · 08-08-2005, 01:49 PM

On my bike, I noticed that the previous owner had cut some slots in the underside of the shift lever. I'm assuming that it was done to weaken it, so that it will break rather than the shaft in case the bike gets dropped.