Worst shifter bolt placement ever!!

This is on my 2005 TC250. Riding with my buddy and my shifter came loose and I couldn't shift...luckily we were on our way back to the staging area and I was able to coast it in. (it was stuck in 4th). What a bitch it was trying to get that thing back tight! I pretty much stripped it with my trackside tools...my buddy was leaning the bike on it's side and pulling up on the shifter but clearance is almost nill.

I ordered a couple bolts and figured I would do better at my garage with all my tools available. First, I figured I would consult the manual in case there was something obvious I was missing. Here's a pic from the manual:



Wow...that's super helpful team Husky, thanks for that. Oh, by the way...what if by some freak set of circumstances...I DON'T HAVE THE FRIGGIN MOTOR OUT OF THE BIKE WHEN I NEED TO GET TO THAT BOLT!!!

I didn't fair a whole lot better in my garage. The frame is in the way which makes getting my smallest 1/4" drive ratchet next to impossible. Even my smallest box wrench has issues because the bolt practically butts up against the shifter arm.

I think I'm done venting now. I started to round the bolt again even in my garage so I guess I'll just order a case of these and call it a day. I am grateful that the Husky is pretty damn easy to work on for most things...this just isn't one of them.

Definitely a pia without a small metric wrench. The closed end is perfect for where this bolt is. I made sure to keep that tool in my tool roll.

maybe replace it with a socket head cap screw (aka allen) and use a ball-end allen wrench.

My kid's 511 is in the same place and I believe it may be worse.

That's actually a great idea! Husky isn't shy with using allens...the front axle allen is the largest one I've ever used before, this would have been a good choice for the shifter at the factory.

I did have my 8mm wrench...the thickness of the wrench prongs didn't allow me to get a good bite on it. I guess I need to find one with super slim prongs.

IIRC, I use my Thorsen 8mm box end on my 310 shifter.

god, I miss american tools. not talking snap-off either.

OTOH, chinese tools have improved in the last 20 years. and why not? half of our steel factories were dismantled and moved over there 30 years ago.

On my 165 I installed a longer OEM bolt which seems to not loosen as easy. I still check it every ride

Yeah 8mm ring spanner(box wrench to you yanks) fits sweet. Get a 12 point type though as you have to take small bites at it. I usually do it up whilst lifting shifter into second gear(highest point of it's travel). No biggy just sounds like you need a different $2 spanner