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Shifter keeps coming loose

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The bolt that holds the shifter on my '02 250sx keeps backing out. I have tried red & blue thread locker (with days before use), a different bolt, washers you name it. I just installed a Sunline Ti lever last night. I ordered a replacement bolt & special washers. If they don't fix it, I am at a loss. I'll have to switch to a clamp on shift lever if the new OEM bits don't sort it out.:busted:

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That seems crazy that loctite wont work, but for a permanent fix, you could drill a hole through the bolt head and safety wire it to the shifter. Or you could fashion a locking tab washer out of some heavy gauge sheet metal (like they use on older style 4x4 wheel bearings)

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....loctite only works properly if both surfaces are oil free. any residue oil in the shaft thread will prevent the glue doing its job. have u tried a spring washer?

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I lost 2 shifters on my 05 300 while out in the woods. 1 time it fell off right when my foot hit it so i found it. The other time, not so lucky. I happened to be a section where I ride miles between shifts so I had no idea where it was. :busted:

I finally did what has been suggested here. I cleaned it well with surface cleaner (brake cleaner) and then properly applied loctite and then saftery wired it. Never came off again.

When your counter-shaft seal leaks at all (which as we all know is pretty common) it runs right down to the shifter and does it's best liquid wrench impersonation.

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weird. had many bikes over the years. never 1 shifter get loose. check the manual for a specific torque of that bolt. hondas are 9ftlb. ktm is probly similar

Consider yourself lucky! How many of those years were on a 2 stroke KTM?

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The bolt that holds the shifter on my '02 250sx keeps backing out. I have tried red & blue thread locker (with days before use), a different bolt, washers you name it. I just installed a Sunline Ti lever last night. I ordered a replacement bolt & special washers. If they don't fix it, I am at a loss. I'll have to switch to a clamp on shift lever if the new OEM bits don't sort it out.:busted:

Just use the two nut locking system.

After numerous problems with my lever coming loose I've never had a problem since using this system + loctite for good measure.

http://www.boltscience.com/pages/twonuts.htm

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Consider yourself lucky! How many of those years were on a 2 stroke KTM?

actually 4 ktm 2strokes. older models however. just now i see they have changed the shifter bolt design, which i wasnt aware of. it used to go through the top/bottom of the shifter and clamp down on the splined shaft. rock solid design used by nearly every manufacturer for 30+ years. strange they would get away from something that worked so well

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I dont see how that would be possible.

Well I ain't Einstein mate and it worked for me. :busted:

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My shifter isn't a clamp on. What you're suggesting, I assume, is to use a longer bolt, and use a jam-nut. Kinda like the chain adjustment bolts. Yeah? Otherwise, I don't see any other way.

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