5 Speed gear lever problem.

[dougal9887]

Well, having a replacement and useable lever, I could afford to try disassembly of my original lever.
Not to difficult as it turned out so I disassembled both and rebuild mine using just the cup washer from the replacement lever.
These pictures illustrate the procedure I used, and hope they may be of use to anyone needing to get one of these apart.

Replacement lever. Chrome rather marked and rubber boot split. If mine comes apart I'll just be using the cup washer from this one.

The anti vibration joint is secure by two punched tabs.

The tabs were drilled out.

The joint was then separated by rotating it with a stilson wrench whilst pulling apart. The wrench does mark the flared section of the joint but this is covered by the gaiter.

Voil?.

The bottom part of the lever was removed from the metal sleeved
rubber bush using a drift. The
remainder can then be dismantled. The new cuts seen in the upper lever are to allow securing tabs to be punched inwards.

Bottom part reassembled.

Top part was pressed back on using a valve spring compressor and just water as a lubricant.

Job done!

Dougal.

[john.p.clegg]

Dougal
Nice one !

I don't have the anti-vibration fitting in mine,just a solid piece with a couple of grub screws to keep it in place,makes it easier to take apart,haven't noticed any vibration coming through,gives it slightly more "feel".

John

[Spyder fan]

Dougal
That's excellent instructions and photos, there really should be an indexed "How To" archive section containing helpful posts like this.