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2005 KTM 525 Exc Gear Shift Lever Keeps Coming Lose

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The gear shifter shaft has a conical shape at the end with longitudinal spline/threads where the lever is attached. The lever has the opposite conical pattern so the threads mesh together. The lever is held on by a machine screw and washers that thread down the middle of the shaft vs. the kind that clamps on from the side of the lever (http://cheapcycleparts.com/model_years/12121-ktm-2005-racing-525-exc-g/assemblies/234258).

Pretty frequently I’m finding that even with Loctite this screw backs itself out and the lever then is lose causing the splines/threads on the lever to get ruined (by design…better to screw up the lever than the shaft). I then have to replace the lever ($$$).

Have you heard of this issue and do you have any tips on how to get the lever and machine screw to stay tightly fastened?

Thanks.

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Red locktight works most times. I suggest replacing the 6mm bolt and using a washer big enough to cover the shifter casting diameter. Use of a standard 8.8 hardness bolt is enough.

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Check to see if you have a bunch of old Loctite in the bottom of the hole that the screw tightens up against. Use a small drill to remove the old Loctite and then run a tap in the hole to clean out the threads. Clean everything, the hole and the screw, with brake cleaner and then apply red Loctite. Should fix the problem.

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If you decide to use red Loctite on this bolt, heat will be required for its removal, otherwise the bolt will break. Torquing the bolt to 10 ft/lbs also helps to keep the shifter snugged up.

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Mine does the same, even with red loctite. You can safety wire it. Search for one of my old posts on this topic- someone replied with a picture of one safety wired.

Damn Austrians have to be different, even when different is BAD. Ve Vill not do it like za Japaneese....

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do you have the correct KTM washers for this part? I have/had 7 KTMs. The only one that came loose was one that I got used and didnt have the right washers. I use blue and the right washers and all is good. Torque to 7ft lbs for a 6mm diam bolt.

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