Nice guide!

The only thing I'd be concerned about is if the lever is bent extensively. Since the metal is so soft, bending it back could weaken it to the point that I wouldn't trust it anymore. Last thing you need is your shifter to snap while you're riding lol

Maybe it would be a good idea to heat the shifter up with a torch and then submerge it in cold water to try and harden it?

 

The lever is soft so that it "does" bend when you drop your bike, if it were harder you'd lose a rear set every time the bike tipped over.
Metal gets harder every time you manipulate it, it would simply snap if it got to that point. If you didn't trust it you could always heat it up and let it air cool, that would make it soft again. Probably too soft.

I would trust it up to the point where it started to crack, if you're shifting hard enough to bend the lever you'll probably need new shift forks too

 

AdamJH, you are a god among men. Worked like a charm.

 

Thanks so much for this tute. I was wondering what to do about my shifter. I might try doing i today.

 

I bend them back on the bike using the box wrench in the tool set. Works well enough, never had somebody stranded yet

Really the same way you did but it goes over the rubber part of the lever and you just bend away, don't forget to use the metal grip thing that goes with it so you don't destroy your hand.

You also don't wreck up the finish on the shifter any more than it is.

 

I bend them back on the bike using the box wrench in the tool set. Works well enough, never had somebody stranded yet

Really the same way you did but it goes over the rubber part of the lever and you just bend away, don't forget to use the metal grip thing that goes with it so you don't destroy your hand.

You also don't wreck up the finish on the shifter any more than it is.

THAT'S WHAT THAT IS????????? My god...that would have been really useful about an hour ago when I was bending my shifter back haha. I was using a towel to make it less painful

 

Ill be attempting a fix on this.
Do you think that's bent too far to be reliable?

 

^ Jesus how did you manage that!? Stomp on it too hard?

 

I clipped a cone going a little fast

The cone bent my shiftier, broke of my bracket. But my non-riding leather shoes didnt even get a scratch on it...what logic ey. So thankful my foot didn't break, or damage any other part of my bike.

Do you think i should replace it, or it could be bent back with out cracking the metal?

 

You would be surprised how malleable metal can be.

And brittle at the very same time.

Bend sloooooooowly. Add a little heat if you can.............even in the oven on high heat for a bit is a neat trick to get it warm if you aint got nothing else.........don't laugh it works. Much more pliable and much less likely to break the warmer the metal is.

 

http://www.ndt-ed.org/EducationResources/CommunityCollege/Materials/Structure/strengthening.htm

Quick read on work (strain) hardening and heat for those interested.
Bending multiple times will harden and also weaken the metal, but if it's heated enough before fracturing then you can bend it back safely.
I know at least one person who broke their rearset bending the shift lever while on the bike. You can see the rearset bending as you put pressure on the lever. I wouldn't trust it.

 

I just want to share my experience with this. The bike was laid down ever so gently after I thought the kickstand was down...it wasn't =\. The lever was pushed inward so it would hit the link? I needed to bend it out somehow. I tried the box wrench technique..no luck. I assembled it and thought it was hopeless. After doing a bit more research I figured I'd try attaching a breaker-bar into the black rubber and pull it towards me. It worked WONDERS!! (use at your own risk in case it snaps your rear set or the bolt).

Here is a picture of the before:

 

Thank you

Wow, this saved me some money! I just recently bought my first bike (Ninja 300, duh) and last night I had dropped the bike on a hill and noticed before I rode off my gear shift lever was bent all the way in...safe to say that ruined my night lol. Luckily today I went out and bought 30 dollars worth of tools and sat outside for just a few minutes and fixed it myself. I'm a 21 year old female and never touched a bike, car, or anything mechanical wise. I decided to change that when I got a bike so this was an awesome first step. Thank you so much. Your tutorial/post was my guidance! Now I can do my beautiful Sunday ride!

 

You're very welcome Sammy!
Thank you for following this tutorial and getting your hands dirty before wasting time and money on a new lever.
I never consider tools a "cost" to fix anything as long as I can use them again for something else.
:waveysmilie:

 

great thread, I actually searched and found this awhile back I think -- something I need to do PO dropped the bike and this is essentially all of the damage

 

That's what I did! I bent it a few weeks back when trying to park it


~Wendy~

 

Finally bent this back today but we took the whole assembly off didn't realize you could twist it off that joint

 

how do you get that little pivot joint off and back on?

 

Just leave it connected. You can bend it back without disconnecting it.

 

The pivot joints can be removed from the connecting rod by unscrewing them (one side is reverse threaded).
They are not sold as individual parts in the fiche, so I would assume they're not supposed to come apart from their mounted locations (it would be incredibly difficult to attach/detach them to/from anything seeing as how it's a greased bearing with no tool attachment surface).

 

Really guys you need that lever to be strong and reliable , you spent thousands on a new bike right?, so bend the old one back fork out 20 smackos for a new one and keep the old fractured one in you kit for a spare

 

The lever is still very strong and reliable despite being bent, it's a complete waste of money to purchase a new one and possibly more money on shipping. I bought the "bargain bike" to save money, not shell it out carelessly.
Also, the lever is not "fractured" after bending. If it is, then you've bent it numerous times and probably need a whole new bike by then.

PS: it's a $40 part

 

Anyone know the specs of the bolt that utilizes the Allen key? It fell out while riding

 

Did you forget to Loctight it? Or was it factory error?

It's a specialty bolt, so you'll need to order a new one. Don't forget the Loctight (blue kind) next time, especially if you don't have a torque wrench. It's only like 2 bucks to secure hundreds of nuts & bolts.
http://www.kawasakipartsnation.com/oemparts/a/kaw/50edeab4f8700223001c8641/gear-change-mechanism
92154A, BOLT, 92154-1034

If it fell out because of factory error, call in that warranty!

 

I have replaced the shifter tie rod assembly, Part Number 39110, and adjusted the height of the shifter lever to accommodate my foot. The following YouTube videos were very helpful:
Gear Shift Lever Adjustment and MotoGp Conversion:
https://www.youtube.com/watch?v=GmtA9w_57Q

How to replace your shifter lever & tie-rod assembly on a 2008 Kawasaki Ninja 250R:
https://www.youtube.com/watch?v=QW6hOAsoe8k

How to replace a shifter on a motorcycle:
https://www.youtube.com/watch?v=2iNMt-_OOUc

How to Set Your Motorcycle Controls to Fit You
https://www.youtube.com/watch?v=twW0ClpyLKc

Sportbike Wrench-Adjusting Foot Controls:
https://www.youtube.com/watch?v=wOJZVRZ91EY

 

According to the Kawa manual, you shall remove shift lever and the pedal as a unit.
If you do that and getting the lever one spline wrong, you won't be able to upshift.
Check really careful on the line and dot indicating correct position.

 

Resurrection to provide a tip.

I low sided several months ago on a 74°F night with cold tires on a hard left turn at 25+ mph. Noobie move, but better slow than faster...

With the bike propped up on the sidewalk leaning towards me, I used the special big wrench in the tool bag and spent 30+ minutes and lots of sweat straightening it so I could ride home instead of calling roadside assistance.

 

how come I can't see the pics. Just bent my lever today sucks

 

Just get a vice grip or something, and bend it back out. That's what I had to do on my 300 when I bent mine a little.

 

got the lever off today. didn't have a 18mm box wrench so I tried to bend it back my hand.. haha not strong enough. I may be looking into buying a folding shift lever that folds up when it hits the ground so it won't bend. Has anyone seen any made for 300 or bought any?

 

Hi Guys, I dropped my bike and bent the shift lever from 0mph (either in neutral or 1st gear), also broke the rearset bracket when I tried to bend the lever back.

I had ordered the bracket for $85 and not sure if I could re-use the shifter or order a new one for peace of mind....

The real problem that concerns me right now is that when I start the bike (with the shifter lever and rearset taken out), I have to kick the kickstand up, hold in the clutch lever to start it. Now that the bike started, the "Neutral" light ISN'T on, I let go of the clutch lever completely and the bike won't move at all (feel like it's in neutral but the light doesn't come on).

Maybe that would be fixed after putting new shift lever in and play around with it? Or is that a serious problem now?