Shifter Linkage Screw Up

NinjaNoob23 · May 12th, 2014, 09:39 PM

Hey guys,

I was hoping my next post with you all would be one of rainbows and butterflies due to a project completed. However……I need to walk the plank of shame on this one for a stupid rookie mistake.

Interested on how stupid my screw up is? Weeeellll here goes…..
I was changing the chain and sprockets on my beastly 250. I put the shifter back onto the rod that the front sprocket is on (cam shaft rod?). Everything is fine and dandy, job complete it's all good. I sit on the bike and the shifter is up a little too high for my liking. I went down to take it off and the screw broke off inside the black coupler that goes onto the shaft. Most likely because Boris the Cave Man (me) overtightened the screw.

Soooo now I'm looking at a half broken off screw in the dang thing with no real hope of correcting the issue. I have gotten half of what is left in there out, problem is that theres a burr where the screw broke off inside and I'm afraid that it has stripped out the threads inside the coupler. Should also be noted that I have not fully gotten the broken screw out, just half of it……

Having said all that, I'm wondering if ya'll have any advice on what I should do from here…….I'm thinking about buying a new coupler and calling it a day.

iamjacob · May 12th, 2014, 10:22 PM

I've never had much luck with screw extractors but that's an option. You'd probably want to run a tap down through the threads afterwards to clean up any buggered threads.

If you have the extractor and the tap you can give it a go but if not the part might be a similar price to the tools.

I'd probably just buy a replacement...

DmbShn41 · May 13th, 2014, 01:55 PM

Probably easier to buy the replacement. Extractors work great only when you still the proper hole, on centered.

crazymadbastard · May 13th, 2014, 02:40 PM

The burr is from the bolt twisting off, i would simply get a reverse drill bit- harbor freight sells it, simply try centering the smallest bit first and go up in size, eventually the bolt piece will simply unscrew out. I guess you could also drill out from the opposite side with a normal bit and it will twist it/push it out.

NinjaNoob23 · May 13th, 2014, 03:43 PM

Quote:

Originally Posted by crazymadbastard

The burr is from the bolt twisting off, i would simply get a reverse drill bit- harbor freight sells it, simply try centering the smallest bit first and go up in size, eventually the bolt piece will simply unscrew out. I guess you could also drill out from the opposite side with a normal bit and it will twist it/push it out.

I was going to do that, but I'm 90% sure that the threads are stripped due to that burr and me twisting the screw inside the coupler.

So I went ahead and bought a new linkage, thing is that it's from a 1996 zx750. Hopefully it'll fit, looks like it will. Guess we'll find out, unless someone knows something I don't?

http://www.ebay.com/itm/191156674843...84.m1497.l2649

alex.s · May 13th, 2014, 04:46 PM

just use a ziptie and some duct tape

NinjaNoob23 · May 13th, 2014, 05:29 PM

Quote:

Originally Posted by alex.s

just use a ziptie and some duct tape

Haha naahh, I think chicken wire and gorilla glue would be the better choice

alex.s · May 13th, 2014, 05:40 PM

not gorilla glue- it expands

DmbShn41 · May 13th, 2014, 05:49 PM

3D print it. That's more reliable...

mgentz · May 13th, 2014, 05:52 PM

drill it, then tap in a smaller screw or bolt. twist like your tightening it as it will run all the way through. use less force next time.

Kscreations08 · May 13th, 2014, 07:53 PM

I had a Polaris 325 Trailboss that blew the centipetal clutch. Didn't have a clutch puller doojiggy so I looked up a DIY using a bolt and some other stuff (go easy on me this was years ago)

Long story short, the soft metal bolt expanded inside and was thoroughly destroyed. It took 3 days with extracters and picks before I gave up and kicked the stupid thing. Took it to the shop and they had it removed, rethreaded, and the clutch belt replaced in 20 minutes. While I am a firm believer that a motorcyclist should work on their own bikes, sometimes a white flag needs to be flown. You could even watch to see how they do it in case it happens again

NinjaNoob23 · May 19th, 2014, 04:40 PM

Put the new linkage on last night and toke a 45minute ride. Even though it is from a 96 ZX750, it fits like a glove and works as intended. Overall I'm a happy camper as far as correcting my screw up is concerned.

Just thought I'd share that the linkage works well if anyone else was wondering.

May 12th, 2014, 09:39 PM	#1
NinjaNoob23 ninjette.org member Name: Nick Location: Jonesboro, Ar Join Date: May 2014 Motorcycle(s): 2011 Ninja 250 Posts: 17	Shifter Linkage Screw Up Hey guys, I was hoping my next post with you all would be one of rainbows and butterflies due to a project completed. However……I need to walk the plank of shame on this one for a stupid rookie mistake. Interested on how stupid my screw up is? Weeeellll here goes….. I was changing the chain and sprockets on my beastly 250. I put the shifter back onto the rod that the front sprocket is on (cam shaft rod?). Everything is fine and dandy, job complete it's all good. I sit on the bike and the shifter is up a little too high for my liking. I went down to take it off and the screw broke off inside the black coupler that goes onto the shaft. Most likely because Boris the Cave Man (me) overtightened the screw. Soooo now I'm looking at a half broken off screw in the dang thing with no real hope of correcting the issue. I have gotten half of what is left in there out, problem is that theres a burr where the screw broke off inside and I'm afraid that it has stripped out the threads inside the coupler. Should also be noted that I have not fully gotten the broken screw out, just half of it…… Having said all that, I'm wondering if ya'll have any advice on what I should do from here…….I'm thinking about buying a new coupler and calling it a day.

May 13th, 2014, 01:55 PM	#3
DmbShn41 Wannabe Reborn Name: Unregistered Location: Cincy Ohio Join Date: Mar 2009 Motorcycle(s): Blue 2008 Ninja 250 Posts: 302	Probably easier to buy the replacement. Extractors work great only when you still the proper hole, on centered. __________________________________________________ " If you're here to show off and prove that your crotch rocket is faster than my Harley, you can leave now. "

May 13th, 2014, 02:40 PM	#4
crazymadbastard I'm crazy,your excuse is? Name: Winston Location: Connecticut Join Date: May 2013 Motorcycle(s): 250 2007 ninja Posts: A lot.	The burr is from the bolt twisting off, i would simply get a reverse drill bit- harbor freight sells it, simply try centering the smallest bit first and go up in size, eventually the bolt piece will simply unscrew out. I guess you could also drill out from the opposite side with a normal bit and it will twist it/push it out. __________________________________________________ My Cafe Racer Build My intro post

May 13th, 2014, 04:46 PM	#6
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	just use a ziptie and some duct tape __________________________________________________

May 13th, 2014, 05:40 PM	#8
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	not gorilla glue- it expands __________________________________________________

May 12th, 2014, 10:22 PM	#2
iamjacob ninjette.org guru Name: Jacob Location: Stockton, CA Join Date: Dec 2013 Motorcycle(s): 2011 250R SE Posts: 326	I've never had much luck with screw extractors but that's an option. You'd probably want to run a tap down through the threads afterwards to clean up any buggered threads. If you have the extractor and the tap you can give it a go but if not the part might be a similar price to the tools. I'd probably just buy a replacement...

May 13th, 2014, 05:49 PM	#9
DmbShn41 Wannabe Reborn Name: Unregistered Location: Cincy Ohio Join Date: Mar 2009 Motorcycle(s): Blue 2008 Ninja 250 Posts: 302	3D print it. That's more reliable... __________________________________________________ " If you're here to show off and prove that your crotch rocket is faster than my Harley, you can leave now. "

May 13th, 2014, 05:52 PM	#10
mgentz Board Member Name: ... Location: WI Join Date: Dec 2011 Motorcycle(s): 250R (street), 250R (dirt) Posts: A lot.	drill it, then tap in a smaller screw or bolt. twist like your tightening it as it will run all the way through. use less force next time.

May 13th, 2014, 07:53 PM	#11
Kscreations08 Fresh Deli Meat Name: Kevin Location: Wilkes-Barre, Pennsylvania Join Date: Feb 2014 Motorcycle(s): 2009 250R Ninja -Neener- Posts: 678	I had a Polaris 325 Trailboss that blew the centipetal clutch. Didn't have a clutch puller doojiggy so I looked up a DIY using a bolt and some other stuff (go easy on me this was years ago) Long story short, the soft metal bolt expanded inside and was thoroughly destroyed. It took 3 days with extracters and picks before I gave up and kicked the stupid thing. Took it to the shop and they had it removed, rethreaded, and the clutch belt replaced in 20 minutes. While I am a firm believer that a motorcyclist should work on their own bikes, sometimes a white flag needs to be flown. You could even watch to see how they do it in case it happens again __________________________________________________ We shall call thee "Seahorse." -Antiant on Couvade Syndrome

May 19th, 2014, 04:40 PM	#12
NinjaNoob23 ninjette.org member Name: Nick Location: Jonesboro, Ar Join Date: May 2014 Motorcycle(s): 2011 Ninja 250 Posts: 17	Put the new linkage on last night and toke a 45minute ride. Even though it is from a 96 ZX750, it fits like a glove and works as intended. Overall I'm a happy camper as far as correcting my screw up is concerned. Just thought I'd share that the linkage works well if anyone else was wondering.
	1 out of 1 members found this post helpful.

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