TE 449 Stripped gear lever

[oregonsage]

While it does appear the BMW/Husky/Kymco may have missed the mark a bit on the shifter, it is a fairly widespread issue due to the goal of making the lever fail before any of the expensive bits inside the transmission....on impact you WANT the lever to strip, but when shifting you dont.

There is some reason that lots of aftermarket levers are available....and it would be nice if the 449/511 were added to that long list of fitments.

 

[9880sts]

well my 511 has stripped its lever too,
Im in australia and new one is costing my $125
kind of pissed of about this , im sure guys riding wr450f dont have this problem
i even rang zip ty racing this morning about there coming soon shift lever
there answer was vague ,
" not something we have done "
havent taken that off the website
ring back in a month ?? so no help there ..

Buy the Gearshift leaver from Halls Cycles. Good price and quick shipping to Australia. I buy most of my parts from Halls and get them shipped to Melbourne.

 

[HusqRacr]

I agree, Husqvarna must have designed the shifter on a Friday night after some Vino! After 2k miles though, I haven't seemed to have the problems that I read other people are having. I think I approach shift levers on my bikes in a different way though. I use a tiny bit of grease on the threads instead of Loc-tite, and I treat it as a maintenance item along with spokes, and other fasteners that like to come loose on all dirt bikes. A simple 1/4" 8mm socket, 1/4" wobbly, and an extension allow you to get right to it (be it shifting the bike down and then back up and hold it). I do a quick check on mine once every couple of months. Being its aluminum on steel with a constant pounding, I never see them as a "set it and forget it" item. Also I found while working on other customers bikes, I either loosen the chain slack, or just quickly pull the chain to replace a lever or adjust it. Nobody asked, but just my 2 cents.. And I can add, that I lost a shift lever during a mx race on my ole 06 KX250F, that I loc-tited, and Never checked..

 

[dorty08]

I had the same problem with my bike, just ordered an aftermarket one off eBay for $70 in Queensland, Australia. Will wait and see how it goes.

 

[Lon]

I had the same problem with my bike, just ordered an aftermarket one off eBay for $70 in Queensland, Australia. Will wait and see how it goes.

Linky?

Dont worry.. found it

 

[Cosmokenney]

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.

FWIW, I found that it is the case that the bolt has a 4 or 5 MM allen head too. I used a T-Handle Allen Wrench. But I had to drop the bash plate off, and put the bike into 2nd gear as per the workshop manual. It seems that, comparing the MY 11 in the workshop manual to the reality of my MY 13, there is less space in there on the newer model. I couldn't get any of my sockets in there at the correct angle, even with the little swivel head pictured in the manual.

 

[Caiman]

Linky?

Dont worry.. found it

Bought one of those a couple of weeks ago as a spare/backup. Looks a lot like the oem, has only a hex head bolt.

 

[jonny08te510]

What a joke who the he'll designed that! my cr500 takes 2mins to do and that was built in 1999

 

[Dangermouse449]

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

I bought an M.C.S. lever here in Australia (Ebay), the splines are cut all the way through the lever, not just the outer edges like the OEM lever.
I had to split the chain to fit it & put a small bend in the ring end of a standard 8mm ring spanner so I could tighten it up one nip at a time.
I carry it in my tool-bag & check it regularly.
All good so far.

http://www.mcsonline.com.au/

 

[tshea529]

Zipty Racing is manufacturing racing quality Billet shifters for the 449/511 in the next two weeks. Part of the design is a better way of tightening the shifter. Retail sales will be through Hall's cycles.

Danny said they never got made. No Plans to make them

 

[9880sts]

I bought an M.C.S. lever here in Australia (Ebay), the splines are cut all the way through the lever, not just the outer edges like the OEM lever.
I had to split the chain to fit it & put a small bend in the ring end of a standard 8mm ring spanner so I could tighten it up one nip at a time.
I carry it in my tool-bag & check it regularly.
All good so far.

http://www.mcsonline.com.au/

So thats the only aftermarket Gear lever for the TE449 and 511.. You have to attach this Info to our PDF file on the FB page...


Good news from BMW today. Just waiting for Oil Gallery and other drawings and animations ....

 

[carel]

Hi There, I have used the gear lever from 2013 te/txc cut in half use the half with spline for gear shaft, then use your stripped gear lever from 449 and also cut on halfway of lenth then weld the 2 together, I have done a few now and no more stripped lever..!!

 

[brett8b]

I can confirm that these Driven Levers DASC-89 work on my 2012 te449, and so far in my experience its lasted much longer than the oem lever

http://drivenracing.com/shop/foot-controls/dirtbike-shifter

 

[Dangermouse449]

I can confirm that these Driven Levers DASC-89 work on my 2012 te449, and so far in my experience its lasted much longer than the oem lever

http://drivenracing.com/shop/foot-controls/dirtbike-shifter

Nice looking part.

Now, if only someone would do a rear prake pedal too......