belfastguzzi Posted June 1, 2004 Report Share Posted June 1, 2004 If disaster strikes when far from home, a roadside repair to the stuck-in-gear box can be done. No special tools are needed and you just need to lean the bike to save the gear oil. The biggest problem is difficult access to the lower allen screws in the side case. I cut down an Allen key to fit. I have seen 'ball-end' keys but haven't looked at them closely. I presume that they are designed to drive at an angle, so one of these might be the best answer. If you have a suspect (2002) bike and haven't changed parts, then checking that you can access the Allen screws and carrying a spare spring in addition to the tools would be a good idea. Otherwise, a broken spring can be repaired if you carry a pair of grips to bend it. Once home, a new ratchet arm with correct size boss can be fitted; unless you carry a spare one of those, or a file to cut down the original one. Pawl arm oe part number: 04235101 Spring oe part number: 04238300 Tools are easily carried. Gear oil saved in leaned-over box. Broken spring, repaired and a new spring. Oversized boss that seems to be the cause of spring breaking. New boss is correct 15mm. Also, repaired, filed down oversize boss. The three gearbox selector springs. Ready for the road again. The full pictures are here. Also see here Link to comment Share on other sites More sharing options...
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