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How many hours/euros to fix a broken gear shifter shaft?

7K views 13 replies 8 participants last post by  kaptainkid1 
#1 · (Edited)
Broke the gear shifter shaft on my Triumph Legend some weeks ago. Gonna get it fixed on insurance for about 600 euro. But my local Triumph dealer says it can come up to 2500-3000 euro and that the insurance company then might buy the motorcycle instead of repairing. The dealaer (approved and recomended by the insurance company) probably want to go "by the book" (Triumph, Haynes) and split the engine, not go through the sump that I got advice about in this forum.
How many working hours is resonable and whats a normal price in euro for replacing that f-ing gear shifter shaft?
Dont wanna have a bad relation with my local Triumph dealer, but should I look for another one?
 
#2 ·
Cost of parts:

Gear change shaft €57.00
Circlip €0.67
Oil seal (if needed) €8.55
Sump gasket €11.37
Sprocket housing gasket €11.00
New gear lever (if needed) €56.89
Gear lever pin (the bit that actually hit the ground) €8.43
Gear lever rubber €5.98
4 Litres of new oil €30
Oil filter €15 (guess)
Silicone sealant for gaskets €6.00 (guess)
Shipping cost €9.00

Total cost of parts including sales tax €259.95

If you want to/can use your old gear lever then you'll save over €70!!!

The biggest cost at a dealer will be labour.

I could do the whole job in a day in my garage without any specialist tools, professionals would do it a lot faster BUT they also wouldn't take extra care of stuff like thoroughly cleaning the sump & oil strainer.

Bring the bike to me and I'll do the whole thing from start to finish for your €600 including parts! I'll even put you up on an inflatable mattress for the night, buy you a pizza dinner, take you out for a few beers afterwards, and still make a profit :D.
 
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#4 ·
Dont know what the cost of a mechanic would be in sweden but here in uk its arnd 60 euro an hr so lets say at the dealer with 10 hrs labour it would be arnd the 1200 euro mark or do it yourself as arfer has said he did an excellent post on it and if i ever have the misfortune to break mine i be having a go myself
 
#5 ·
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#6 ·
Thanks Hawk and again ArverBrick. Even if I have had motorcycles for about 25 years of my life unfortunatly I´m not a handyman kind of guy. I called around a little and found other Swedish dealers that known this gear shaft problem and also had fixed it via the sump. They thougt the job totally with parts should cost maximum some few hundreds euro more then the 6-7000 euro I have to pay to my insurance -company. I give my local dealer a bit more time because its important to have a good relation if you are not good with the mech. When its fixed I do something to weaken the gear shifter so it breaks first, I have seen some nice solutions here at the forum, including put on a motocross-shifter that can bend. But I probably take the easyest way I read about - just drill a 5,5 mm hole through the shifter. What do yo think abaout that?
 
#7 ·
Drilling Shifter

It is not necessary to drill right through the shifter, go in from the back and drill 3 x 4mm holes approx. halfway through the alloy. This will weaken it sufficiently in case of a drop but still maintain enough strength for normal use.
Good luck.
 
#13 ·
If it broke at the narrow part where the retaining bolt goes, and if you have access to a drill press, or a machine shop, you might be able to drill down the length of the broken part, then use that as a drill guide and drill right into the rest of the shaft. Tap the hole in the shaft and use a small bolt to bolt the broken piece in place. (Next time you drop it it'll break the small bolt...)
 
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