Gear shift lever replacement-bushing

[dtromp]

Hello fellow Himi fans, my wife has dropped her 2021 Himalayan a couple of times and bent the gear shift lever. I have straightened it a couple of times, but it is getting stressed and now rusted since the paint has chipped. I bought a replacement, but it does not have the black nylon bushing in the hole that the installation bolt goes through. I managed to press the original bushing out, but am having problems installing it in the new gear shift lever assembly. Has anyone had any experience with this?

Thanks in advance...

 

[Alan F.]

Freeze the bushing and heat the lever to increase clearances?

 

[dtromp]

Freeze the bushing and heat the lever to increase clearances?

I will try freezing the bushing, but heating the lever might melt the bushing?

 

[Alan F.]

Hot to the touch, not hot enough to melt the bushing.

 

[dtromp]

Hot to the touch, not hot enough to melt the bushing.

Thanks. I gave it a try and ruined the bushing. I will try to source a replacement and maybe have the dealer try...

 

[Alan F.]

I'm so sorry this happened. Perhaps a short length of copper tubing might make a well fitting bushing?

 

[Eatmore Mudd]

There's a decent chance the polymer bushing was "mushroomed" a tiny bit on the end from being pressed out.

The vendor you got the lever from can probably get you the bushing too.

McMas-Carr probably has something similar that will fit and work.

Any local Vo-Tech college should have a machinist course and any student there could turn a replacement bushing on the lathe.

Just throwing some ideas out there.

 

[dtromp]

There's a decent chance the polymer bushing was "mushroomed" a tiny bit on the end from being pressed out.

The vendor you got the lever from can probably get you the bushing too.

McMas-Carr probably has something similar that will fit and work.

Any local Vo-Tech college should have a machinist course and any student there could turn a replacement bushing on the lathe.

Just throwing some ideas out there.

Thanks Mudd, great leads. McMas-Carr (and a couple others) don't have the 25mm long, 12 mm ID, 14-15 mm OD bushing. The dealer doesn't even show a bushing on the parts fiche, nor does Hitchcock's. Weird.

 

[nmroadrunner]

Have you tried Tractor Supply or Home Depot?

 

[Alan F.]

12x14x25 Ebay

12x15x25 isn't so easy to fimd

 

[dtromp]

Have you tried Tractor Supply or Home Depot?

Ace and Home depot

 

[dtromp]

Found a bushing at McMaster-Carr. Should be here by Wednesday. Now for the install....

 

[Roy Gavin]

I changed my lever and the new one came with the bush, but not the bolt.
Pity as the lever was wider than the original and needed a longer bolt too.
Managed to cut the lever down , but the bush was also too small for the bolt, and had to be cleaned out with a 12mm drill - is had compressed in during filling.
So take a bit care, clean and polish the hole in the lever and perhaps put a slight taper on the end.
Do the same with the bush, it is surprising how much easier even a thou or two off makes when it comes too fitting a bush.

 

[Alan F.]

Also please don't hammer the new bushing into place. If you have access to a hydraulic press or an Arbor press use that, but most of us would use a bolt, nut and a couple of fender washers to slowly press the new bushing into the lever.

 

[tom_d]

Thanks Mudd, great leads. McMas-Carr (and a couple others) don't have the 25mm long, 12 mm ID, 14-15 mm OD bushing. The dealer doesn't even show a bushing on the parts fiche, nor does Hitchcock's. Weird.

I noticed the same on Hitcocks site. I wonder if it might be included with the pivot pin part I think bolts through it. Hitchcocks might know, and would likely be curious about your situation.
Pex tubing - people use it as diy replacements for door jam striker bushings in the auto world, it sounds like it is up to task. The 1/2” ID tubing should be fairly close to 12mm and about the right OD as well. About 5 bucks to try.
There are lots of online options for custom parts there days. This guy might could help with a delrin replacement which probably is superior.

CUSTOM DELRIN/ACETAL Plastic bushings, made to YOUR SIZE, QUANTITY, and SPECS | eBay

I can make you custom delrin/ acetal bushings(headless, or with flange). (1) CUSTOM DELRIN Plastic bushing for pbsch929 (#192456530266). (4) CUSTOM DELRIN/ACETAL Plastic bushings, for smag2977 (#192467863146).

www.ebay.com

And a business which makes lots of bronze bushings and can do some custom sizing for you. They offer 7/16” ID along with the 1/2” below, actually scores of sizes so one should be quite close and not need much touchup

Sleeve Bearing

With over 900 different sizes available for immediate shipment, Sleeve Bearings provide and off-the-shelf, economical, and fast solution. They come in both SAE841 (oil impregnated) and C93200 alloys.

bronze-online.com

This is an interesting question and one another of us will surely face, I look forward to its answers.

 

[Bluestrom13]

I noticed the same on Hitcocks site. I wonder if it might be included with the pivot pin part I think bolts through it.

It's part of the lever - or should be.


Also, as Roy discovered, there are 2 different widths of lever boss - 18mm and 25mm. Respective pivot pins are supplied separately.
There is provision made on the wider lever to fit an O-ring each side of the boss.

 

[Dool2]

I noticed the same on Hitcocks site. I wonder if it might be included with the pivot pin part I think bolts through it. Hitchcocks might know, and would likely be curious about your situation.
Pex tubing - people use it as diy replacements for door jam striker bushings in the auto world, it sounds like it is up to task. The 1/2” ID tubing should be fairly close to 12mm and about the right OD as well. About 5 bucks to try.
There are lots of online options for custom parts there days. This guy might could help with a delrin replacement which probably is superior.

CUSTOM DELRIN/ACETAL Plastic bushings, made to YOUR SIZE, QUANTITY, and SPECS | eBay

I can make you custom delrin/ acetal bushings(headless, or with flange). (1) CUSTOM DELRIN Plastic bushing for pbsch929 (#192456530266). (4) CUSTOM DELRIN/ACETAL Plastic bushings, for smag2977 (#192467863146).

www.ebay.com

And a business which makes lots of bronze bushings and can do some custom sizing for you. They offer 7/16” ID along with the 1/2” below, actually scores of sizes so one should be quite close and not need much touchup

Sleeve Bearing

With over 900 different sizes available for immediate shipment, Sleeve Bearings provide and off-the-shelf, economical, and fast solution. They come in both SAE841 (oil impregnated) and C93200 alloys.

bronze-online.com

This is an interesting question and one another of us will surely face, I look forward to its answers.

A meter of Tubing would make a lot of Bushes.

 

[Bluestrom13]

The 1/2” ID tubing should be fairly close to 12mm and about the right OD as well.

If it's not an exact fit / won't fit, then a lengthwise saw cut will enable a slight oversize to be accommodated?

 

[tom_d]

It's part of the lever - or should be.

OK, I'm stumped. If @dtromp didn't get a plastic bushing, is it because it was left out and missing from his (correct?) replacement shifter or did the earlier original 17mm wide shifter not have one and he received one of those?

It does look like the original variant "A" is on eBay, actually quit a few, so it's possible in theory to get the wrong one.

@dtromp , I took mine apart for pictures in case it is helpful, there is definitely a plastic bushing standing proudly on the shifter of my 2019, and there are 2 o-rings on the pivot as @Bluestrom13 pointed out. I would be curious if the replacement you received is 25mm wide at this point on the shifter or 17mm?


sorry for the blurry pictures, my shoulder is banged up at the moment and I didn't realize.

Gear Shifter Assembly for Royal ENFIELD Himalayan 574683/a S2u for sale online | eBay

Find many great new & used options and get the best deals for Gear Shifter Assembly for Royal ENFIELD Himalayan 574683/a S2u at the best online prices at eBay! Free shipping for many products!

www.ebay.com

 

[grymsr]

I found an ebay listing for a 2018 that was being parted out and snagged the entire shifter assembly for $40. Check around and you may be able to replace the works for low bucks.
Try:

Muffs Motorsports
or

PinWall Cycle Parts Inc
Both are reputable dealers