Latest changes

SpartanDen · #1 17th June 2007

OK... so I bought a set of forward controls from someone on the forum. They came, I checked 'em out, and found there was not shift lever (shift lever was retained by previous owner to accomodate their set up) so I ordered one from my local indepenent. Took two weeks, but then I was in no hurry. Finally got the shift lever and did the change today. Kinda a pita to make the change, but it could have been worse. did remove the rear pipe to facilitate removal of the front sprocket cover. And I did not remove the foot peg mount to install the right side bracket. A tight fit to say the least. Got the right side done and wasn't as bad as I caught. Went to do the shifter side and found the new lever will not accept the old shcs from the mid shifter. I guess the original shifter was 1/4-20 and the new shifter is 5/16-18 thread. So I have a bolt temporarily in until I can get a replacement. Then removed the stock left side foot peg...the two bolts that hold it on are 5/16-18 x 3" long shcs. And I did not have anything shorter...so washers stacked to cover the slack until I get proper bolts. So once I got these temporary fixes in place, there seems to be a bit of slop in the shifter. Could this be a worn bushing? Should there be slop there?
So my question is.... slop or not? Anyone had any issues with changes such as these and had fasteners issues??

Bruce · #2 18th June 2007

Denny, I 've got forward controls on mine ,they are stock. I've had a little slop in mine also. I've never checked to see if the bushing can be replace but I do slide mine off and grease it a couple time a year. I've also found some rubber o- rings that I fit between the lever and take up some of the slack and vibration.

rickxx · #3 18th June 2007

i put the forward controls from my wife's 03 on my 96. don't recall any issues with the fasteners. it was a pain working one side then the other....took a while. the spline on the mid control shifter was on there pretty good but finally got it off. no issues w/ slop in the shifter.

SpartanDen · #4 19th June 2007

Bruce.... what size o-rings did you use? I'm thinking of pulling the shifter off in the next few days if it rains and check to see if there is any wear. I have some good waterproof wheel bearing grease I used in the dirt bike racing days I'll prolly lube up the shifter.
I just wasn't sure if there should be some slop or not...it appears we may have a bit out of the ordinary. A trip to the dealer and some calipers may give me a good idea if it is worn.
Thanks!

Bruce · #5 19th June 2007

Denny,, I really can't tell you what size. I've got an old o-ring kit from work that I tried a size till it fit good. You can probably find one at the hardware store. It was close to 1" in dia. and about 1/32 thick, I used one on each side of the lever for the shifter and brake, Make sure the brake side is not to tight , it will not return and keep brake light on.