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The teeth on the shifter (and probably the shaft too) wear out over time. And if your like me from the constant shifts into a non existant 7th gear.
What I did was:
1. replace the bolt , it had definatly stretched.
2. used a dremmel (or small file) to grind off the teeth on either side of the slot where the bolt goes.
3. used a small cut-off wheel to make the above mentioned slot wider.
Whats happening is as the teeth wear, you start to get slop in the shifter. Just tightening the bolt only stretches it because the teeth on either side of the slot pull up against their coresponding teeth on the shaft, stopping the clamping force from working all the way arounf the shaft.
Removing the first couple of teeth lets the force spread a little further around, but since the shifter is aluminium it stretches around the shaft and completely closes the gap before the shifter is completely tight.
So now using a cut-off wheel you need to make the slot wider so you can have more room to tighten the bolt.
Of course eventually the slop will come back and you'll need to do this all over again until the shifter break, but who knows how long the will take.
Used to do this once a year on my old kx250, until I replaced the shfter with a heavy duty steel one. But that opens up an entirely new batch of headaches.
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kubbie
"I'll call you if you need me"
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