TE 449 Stripped gear lever

[marty75]

My mate has a 2011 TE449 and he has stripped the spline of 2 gear levers now. The bolt to tighten the lever is very hard to get at. Has anyone else had the same problem? If so how did you fix it so it doesn't happen again?

 

[cam]

My mate has a 2011 TE449 and he has stripped the spline of 2 gear levers now. The bolt to tighten the lever is very hard to get at. Has anyone else had the same problem? If so how did you fix it so it doesn't happen again?

ive gone thru a gear lever in the 1st month i had my te449. my guess it was a pre delivery problem rather than a faulty part. it was replaced under warranty and after doing another 500km i checked the lever again b4 my last ride and it was loose so i tightened it so that it wld get me thru a day of riding. now im going to remove the lever to check and make sure that spline it ok and if its all good i will put it back on and try locktighting the bolt

 

[twmtatenrost]

When I had my 449 I went through 2 levers in 10 months. I tried increasing the gap on the gear lever-- no good, locknut--no good. Channged for other reasons to a 310-- that doesnt start.

Drill a hole in the bash plate and you can then get an allen key/ socket onto the bolt easier to tighten it . Again frustrating.

 

[waserman]

I've got a 510 and I check mine every time I do my oil changes,or every day on multiple day rides. I've found on several occasions that it has come loose, so I started using a torque wrench and blue loctite on it and that seems to have helped. If you over tighten it, it will stretch or break and thus become loose again.I've had other than the Husqvarna brand on the bike and it seems to me that the Husqvarna is the best one IMO, you just have to check it because of the vibration I believe(my bike does vibrate).

 

[Motosportz]

TE511 with 3300 miles, zero issues. I use one of these style wrenches to get in there and check it once in a while. I ride mine off road a lot and the shifter is well used.

 

[MotoMarc36]

About half the bikes/atv's I service have loose shifters! It's something I check on every bike that comes through. It is not a Husky problem so much as a problem in general! It is almost impossible for an aluminum shift lever to damage the hardened steel splines.

 

[Motosportz]

About half the bikes/atv's I service have loose shifters! It's something I check on every bike that comes through.

Yep, when you have a long lever you smash with your foot that's held on with a 8mm pinch bolt you need to check it often.

 

[oregonsage]

Yep, when you have a long lever you smash with your foot that's held on with a 8mm pinch bolt you need to check it often.

I remember having this problem with my 1974 SL 100 Honda, and a handful of bikes since...however my 511 has stayed snug from the start. Once it loosens or stretches you are screwed.... shifter clamps are something begging for a better mousetrap.

 

[Rearwheelin]

Maybe this issue happens to prevent shifting fork damage ? I keep mine tight no issues here. Seemed a little loose from the factory.

 

[Croc]

I'm on my second in 6 mths. Its not being tight is not the issue. Mine currently has stripped the outer spline & the bolt is still tight. The problem I think is the spline on the lever does not go all the way through & is to soft. Now if someone could make a new lever & fix the issue I don't think there will be a problem. I know of several 449/511s having the same issue. On all the bikes I have owned in the past, this has never happened, the only time I have had an issue was when I broke one.

 

[B3NO-511]

Yeh im on my second. Is there any Aftermarket Levers around?

 

[Croc]

Yeh im on my second. Is there any Aftermarket Levers around?

Apparently not, I did ask about 2 weeks ago. Definitely non in OZ

 

[Caiman]

Might have to start emailing Driven, Hammerhead etc, see if they'll start making one.

 

[Londin]

Guys guys guys......the middle of the bolt is an Allan key - takes a minute to get to!!

 

[twmtatenrost]

Aye,
thats why if you drill a hole in the skid plate in line with the bolt you can tighten to your hearts content. Shame it comes loose again though

 

[B3NO-511]

Yeh its not the bolt thats the problem, but the soft Ally splines. On my second lever, i filed the gap a touch bigger, loctite, blah blah, Was checking it every couple of rides and it was still coming loose. Maybe im just to hard on my shifts

 

[tommey_c]

I had my swingarm off the bike the other day changing the front sprocket and found it very easy to get to with the swingarm removed, a bit of a hassle just to tighten one bolt i realise.

 

[Alvsey]

Same issue lads, lever comes loose regularily, installed a slightly longer allen key bolt and installed a lock nut also. Tighten bolt, then nut, then bolt and so on until its tight as. Has not come loose since. Its still a pain in the backside to get at and fiddly as unless you pull the swing arm out the way but, no pain, no gain !!!

 

[TE in RC]

Same issue lads, lever comes loose regularily, installed a slightly longer allen key bolt and installed a lock nut also. Tighten bolt, then nut, then bolt and so on until its tight as. Has not come loose since. Its still a pain in the backside to get at and fiddly as unless you pull the swing arm out the way but, no pain, no gain !!!

I found mine loose as well. Could not make it tighter so I will be getting the longer bolt with lock nut. Thanks. As mentioned earlier I will remove the swingarm to gain access, it will be good to check the bearings too!

 

[marshwater]

Just happened today for the first time. What a bitch to get to. Who did you order your replacement from? And did it come with a new bolt? Do you have to remove the chain to place the new lever?