Selector Box Rebuild

Hammer
  • Hammer
  • Small slotted screwdriver
  • Micro slotted screwdriver
  • pick
  • punch
  • pliers
  • vice grips
  • wire brush
First in inspect the selector box for any obvious damage

First in inspect the selector box for any obvious damage

Begin by removing the small pivot screw this can be tricky
  • Begin by removing the small pivot screw this can be tricky
  • this is a high wear part and should be replaced
this trick sometimes is necessary
  • this trick sometimes is necessary
  • attach the vice grips to the micro screwdriver and use them for leverage
once you break it free you can finish removing it by hand

once you break it free you can finish removing it by hand

you may have to use the pliers to get the pin out

you may have to use the pliers to get the pin out

once you get it out the selector lever and spring can be removed.

once you get it out the selector lever and spring can be removed.

inspect the roller and replace it if its worn out or has and grooves

inspect the roller and replace it if its worn out or has and grooves

next use the punch to remove the pin that holds the arm to the top part of the selector box
  • next use the punch to remove the pin that holds the arm to the top part of the selector box
  • the pin is tapered so it will only come out one way (with the arm pushed all the way in as if it were in 1st gear).
after you get it started spin the arm the other way (as if it were in 4th gear) and pull the pin out with the pliers

after you get it started spin the arm the other way (as if it were in 4th gear) and pull the pin out with the pliers

with the pin out the two pieces are separate and you can slide the top part off

with the pin out the two pieces are separate and you can slide the top part off

this is what you should have

this is what you should have

inspect the teeth for any wear
  • inspect the teeth for any wear
  • this can be a cause of your bike slipping out of gear if the teeth are badly worn.
remove the cable adjusters

remove the cable adjusters

Step photo
these are all the parts of the disassembled selector
  • these are all the parts of the disassembled selector
  • clean all the parts that you are going to reuse
use the wire brush to clean the mating surface to prevent oil leaks

use the wire brush to clean the mating surface to prevent oil leaks

grease the shaft

grease the shaft

insert the shaft into the box

insert the shaft into the box

when its about halfway in insert the selector lever

when its about halfway in insert the selector lever

make sure they are lined up and push it the rest of the way in

make sure they are lined up and push it the rest of the way in

line up the holes and insert the pin
  • line up the holes and insert the pin
  • remember its tapered so stick the smaller end in first
finish the job with a hammer

finish the job with a hammer

now slide the selector lever in and line up the holes
Step photo
tighten it down with a screwdriver as tight as you can get it

tighten it down with a screwdriver as tight as you can get it

finally insert the spring and your almost done!

finally insert the spring and your almost done!

there is an indentation that accepts the spring on the body of the selector

there is an indentation that accepts the spring on the body of the selector

reinstall the cable adjusters
Step photo
install it on the motor with a new gasket

install it on the motor with a new gasket