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Old July 27th, 2009, 02:21 PM   #1
Jax1512
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Shift Lever Bolt Fell Out

I was a little surprised by this however, my bike is brand new with only about 280 miles on it. I had been riding about 90 miles and was on my way home when I went to shift down at a light out of 6th gear and noticed my shift lever was just dangling. I was able to pull off into a parking lot (still in 6th gear) and just happened to be across the street from an auto parts store. My boyfriend and I went in to find a bolt that would be a 'best fit' to get me the last 4 miles home.

I am a newbie rider and was wondering what could have caused this? Poor shifting, I don't think I stomp on it at all, or could it possibly be a manufacturer assembly issue?

Looking for input as if it is a user error I don't want it to happen again.

T
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Old July 27th, 2009, 02:24 PM   #2
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sadly, it's an all too common occurrence. Check your bolts often, and consider putting some blue locktite on there to help it stay put. It's nothing you did in your technique - you just need to keep an eye on those bolts. Someone else recently posted about this happening on the way home from their 600 mile service.
congrats on safely remedying the situation!
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Old July 27th, 2009, 02:27 PM   #3
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Definitely not rider error.

If you've never touched that bolt then it sounds like a complete manufacture assembly issue.

Take it back to the dealer and demand they fix it. Make sure they put a drop of loctite on it too.

I would be so mad..
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Old July 27th, 2009, 02:34 PM   #4
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I definitely took it into the dealership and they are waiting for the bolt to come in and they are going to put some loctite on it.

Hopefully I will have it back on Wednesday.
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Old July 27th, 2009, 06:43 PM   #5
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you'd just about take it for granted that when you get a new bike, everything is good to go leaving the dealership, yet this sorta thing happens. although i've never had this happen to me with new vehicle, when i got my bike ('03 w/1800mi.) i gave it a good look over making sure hardware was secured. i missed a few minor things, but nothing that resulted in someting falling off. make it a point to remind the dealer when you pick up your cycle from its first scheduled maintenance servicing about what happened, and his assurances that this time, everythings REALLY good to go.
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Old July 27th, 2009, 10:07 PM   #6
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i alway check that bolt, so far so good. hear the motor mount bolts might buzz loose. anyone have that problem?
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Old July 28th, 2009, 12:14 AM   #7
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Quote:
Originally Posted by backinthesaddleagain View Post
i alway check that bolt, so far so good. hear the motor mount bolts might buzz loose. anyone have that problem?
yup that is one of the first bolts i check when making sure all the bolts and nuts are tight on the on the bike. I've had that happen to me on the freeway and it wasn't fun pulling over to find a allen to tighten it. Turns out i didn't have anything in my tool kit so I hand tightened it and drove it home and tightened it there. Once you do it a few times, you can do all the bolts and nuts on the bike in less than 10 mins. I usually check these bolts and nuts every few thousand miles after the first time.
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Old July 28th, 2009, 12:42 AM   #8
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I think that the agency that sold the bike are responsible for this, they unpack the bike and put most of the sticky out bits on or at least they do in Switzerland. After reading number of threads on louse bolts I have checked mine and all have been tight.

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Old May 20th, 2011, 01:54 PM   #9
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HELP Shifter fell off

While i was riding my i tried to downshift and my whole shifter kinda collapsed .. i pulled over on the side of the road and this bolt that holds it to the bike seems to be missing.. its gonna take a week to get one shipped into the dealers and i cant leave my bike at some parking lot for that long..

does anyone know if i can just get a bolt from a hardware store and just temporarily put it in for the 15 minute ride home...

the part number is 92002-1926

What size temporary bolt can i get if any ?
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Old May 20th, 2011, 02:06 PM   #10
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Don't know how long they are or what thread pitch, but it's a 10mm bolt. I can measure it when I get home.
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Old May 20th, 2011, 02:45 PM   #11
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Sounds like it's an M8x1.25 bolt, not sure on length though. I'm sure you could use one from a hardware store temporarily.
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Old May 20th, 2011, 05:11 PM   #12
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Is it the same as the ones holding on the left passenger peg?
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Old May 20th, 2011, 07:31 PM   #13
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I couldn't find my tape measure, but it looks to be 10mm by 1.25. The bolt on top is the bolt you need and for frame of reference, the longer bolt on the bottom is from the clutch perch.

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Old May 20th, 2011, 07:46 PM   #14
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A common issue on this bike and one of the items people need to check regularly. Same probably goes for a lot of other bikes. I recall someone who had this issue ended up using a 8x1.25 bolt as a substitute for the OEM bolt. Probably wasn't a perfect match but it did the job nonetheless.
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Old May 20th, 2011, 07:50 PM   #15
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Quote:
Originally Posted by Cuongism View Post
I couldn't find my tape measure, but it looks to be 10mm by 1.25. The bolt on top is the bolt you need and for frame of reference, the longer bolt on the bottom is from the clutch perch.

Uhh... but his is a round headed allen bolt.
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Old May 20th, 2011, 07:56 PM   #16
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Oops, you're right, I never looked closely at the pic since I'm on my phone and the image is tiny. From the description, I thought he meant bolt that held the rod to the bike.
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Old May 20th, 2011, 09:39 PM   #17
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haha thanks guys but the replies didnt come soon enough so i ended up going to the store buying like 10 different bolts and fortunately one kinda (not really) fit.. atleast enough to get me home,but i had to hand tighten the bolt at every stop
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Old May 21st, 2011, 07:53 AM   #18
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Same thing happened to me. I replaced it with a bolt from my vast collection of bolts, a lock washer, and a bit of blue locktite.
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Old May 21st, 2011, 03:53 PM   #19
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Quote:
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Same thing happened to me. I replaced it with a bolt from my vast collection of bolts, a lock washer, and a bit of blue locktite.
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Old May 21st, 2011, 04:01 PM   #20
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I check that bolt everyday that I ride.
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Old May 29th, 2011, 01:12 PM   #21
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I wish I had read this earlier... especially the part about checking it often. My shifter fell off today!
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Old May 31st, 2011, 04:00 PM   #22
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The same thing happened to me on a low speed turn, I stepped down to downshift before the turn, after i came out of the turn, i tried to upshift and noticed that there was nothing there for my foot to hook on, i look down and noticed that the shifter was hanging on, luckily the bolt and washer were still hanging onto the shifter portion.

Now I check it and make sure it's not loose every day before i pull it out of the garage for rides.
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Old May 31st, 2011, 04:34 PM   #23
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Hey so I ended up getting a metric 8 x 40mm bolt and it works fine , now i just need to get this blue locktite that everyone speaks of.. cost me 80 cents as opposed to 16.00 $$ for the same peice at the dealership.
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Old May 31st, 2011, 06:14 PM   #24
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Yeah, mine loosened up, and was about to come off back when I first got it. That thing is notorious for coming loose and falling off. I ended up drilling and tapping the rearset for a set screw to make sure it never came loose again.
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Old May 31st, 2011, 09:18 PM   #25
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Quote:
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The same thing happened to me on a low speed turn, I stepped down to downshift before the turn, after i came out of the turn, i tried to upshift and noticed that there was nothing there for my foot to hook on, i look down and noticed that the shifter was hanging on, luckily the bolt and washer were still hanging onto the shifter portion.

Now I check it and make sure it's not loose every day before i pull it out of the garage for rides.
EXACT same thing happened to me on a group ride....luckily when I pulled over the bolt was just resting on my boot and hadn't fallen down.
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Old June 1st, 2011, 06:28 PM   #26
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Exact same thing happened to me when I was riding on the highway! I went to downshift from sixth and my toe swept well past where the shifter should have been. The bolt must have fallen out sometime between entering and exiting the highway.

I nursed it to the dealership (where I was headed anyway, it so happens) and they replaced it for me. The tech also claimed that missing blue Loctite was probably the source of the problem.

Make sure to check this bolt often!!!!
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Old June 1st, 2011, 07:10 PM   #27
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Makes me want to carry around a spare.
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Old June 2nd, 2011, 10:51 AM   #28
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Similarly, I once had the the linkage arm on the shifter "adjust" itself due to the vibrations. I didn't loose any parts, but the shifter moved so far down that I couldn't downshift (discovered this at a light). Punishing my clutch got me into a parking lot with 2nd gear. The crappy toolkit actually came in handy, as re-tightened the nuts and headed home. Blue locktite now, baby! No problems since.
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Old September 27th, 2011, 05:58 PM   #29
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Lost mine at the start of a group ride of 600km. Luckily the Honda cbr250 uses a bolt of the same size to hold its muffler. I borrowed it for the day. Now waiting for the part to come in.
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Old December 13th, 2012, 08:11 AM   #30
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Question gear shifter bolt

Hello all,

The bolt to my gear shifter fell off. Did realize it until the other day I was riding and tried to down shift. Had to pull over and put it back in place. Does anyone know what size bolt that is?
Thx in advance.
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Old December 13th, 2012, 08:17 AM   #31
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If you mean the one that clamps around the shift rod that runs through the case, its M6 x 20
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Old December 13th, 2012, 09:30 AM   #32
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Old December 13th, 2012, 10:04 AM   #33
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If you mean the one that clamps around the shift rod that runs through the case, its M6 x 20
Has a flanged 10hex head as well. Check the knurling spline and make sure you didn't screw it up from shifting without out the clamping force of the bolt to keep it all tight. The shifter side will wear first but if you let it go long enough it it chew up the shift shaft going through the motor then you'll be pulling you motor apart to replace it.

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Old December 17th, 2012, 05:54 AM   #34
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Thumbs up

My apologizes for bit posting a picture. Yes that's the one.

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Old March 27th, 2013, 11:27 AM   #35
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PSA: check your shifter bolt once in a while

So this Sunday, as I was riding back to campus, barely a mile from the parking lot, I go to downshift, and I miss the shifter. Confused, I think that I moved my foot wrong and try again. Still no shifter. I look down and see that it looks bent, which is weird since it was fine for the past hour of the ride... So now I'm stuck in 5th or 6th gear, so if I stop, I'll be stuck. Thankfully, there's a campus parking lot nearby (not the one I usually park in) where I manage to pull over safely. Pull in clutch, shut off the engine, get off and remove my helmet to see what's up.

Turns out the bolt for my shifter fell out, and now it's just hanging there...

Anyway, I later pushed/rode my bike to the motorcycle parking (turns out feathering the clutch enough will get you going in any gear, but I can't imagine it's good for the clutch... hah), before ordering a replacement. Until it arrives, no riding for me...

So yeah, if I had checked it even once in the past couple months this probably wouldn't have happened.
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Old March 27th, 2013, 11:34 AM   #36
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These bikes are really buzzy. My engine mount bolt vibrated itself loose once. You have to check everything periodically.
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Old March 27th, 2013, 11:39 AM   #37
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/merged a few "shifter bolt falling out" threads

It's a pretty common problem, unfortunately. Fortunately, it's not hard to remedy once made aware of the issue.
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Old March 27th, 2013, 12:48 PM   #38
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........So yeah, if I had checked it even once in the past couple months this probably wouldn't have happened.


What do you guys do each Saturday?............that is maintenance day !!!
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Old March 27th, 2013, 12:58 PM   #39
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What do you guys do each Saturday?............that is maintenance day !!!
Everyday is maintenance.......or was it Mod day well anyways I'm impressed I've only lost one bolt(fairing bolt) in the 1-1/2 years I've owned and dozens of time I've taken apart my bike.

I had my kick started lever fall off the RM-Z250 like two weeks after I bought it, that was a $200 oops
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Old March 27th, 2013, 01:03 PM   #40
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...........I've only lost one bolt(fairing bolt) in the 1-1/2 years I've owned..........
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