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Les Kerf 
Orange Level
Joined: 08 May 2020
Location: Idaho
Points: 1256
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 Topic: HD5G Shifter Repair
Posted: 10 Mar 2022 at 8:13am |
I installed the repaired shifter last week, it sure works smooth and tight now  I brazed the holes up solid and drilled new holes to be a slip fit for the 3/8" roll pin. The center piece was hopelessly worn out so I made a new one and drilled it for a tight fit on the roll pin. The side support bolts were quite worn so I built them up with brazing rod, then hand-filed them to a nice sliding fit. This took a couple of hours per bolt, but lacking access to a lathe now that I am retired I took the cheap way out  I expect this to outlast me.  
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Coke-in-MN
Orange Level Access
Joined: 12 Sep 2009
Location: Afton MN
Points: 41979
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Posted: 10 Mar 2022 at 11:48am |
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hope your roll pin works , I used a piece or drill rod for cross pin - then made bolts on lathe and ground a relief in drill rod for end of bolts to index into to retain the rod .
Then whatever works is better than a worn unit .
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Life lesson: If you’re being chased by a lion, you’re on a horse, to the left of you is a giraffe and on the right is a unicorn, what do you do? You stop drinking and get off the carousel.
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clark66
Bronze Level
Joined: 29 Dec 2011
Location: south jersey
Points: 11
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Posted: 11 Mar 2022 at 8:13pm |
Thank you for posting these pictures. I would like to make this repair sometime soon on a HD5G that I acquired last fall. The shifter is completely loose and very hard to get in gear.
Was also taking a closer look at the bushing wear on track and was curious if anyone could give their opinion on how much is left on this bushing before it gets to exposing the pin? It seems like at least a good 1/8 inch  or more of material has worn away- I would imagine that they should be at least turned soon- before its too late.
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Coke-in-MN
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Joined: 12 Sep 2009
Location: Afton MN
Points: 41979
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Posted: 11 Mar 2022 at 10:10pm |
It's to the point DO IT NOW before it wears through . There are a couple other posts on repairs to the shifter on this site .
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Life lesson: If you’re being chased by a lion, you’re on a horse, to the left of you is a giraffe and on the right is a unicorn, what do you do? You stop drinking and get off the carousel.
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clark66
Bronze Level
Joined: 29 Dec 2011
Location: south jersey
Points: 11
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Posted: 12 Mar 2022 at 12:31pm |
Found the other posts related to the gear shifter repairs, Thanks  Does anyone happen to know any outfits that do track press work that would turn the pins and bushings in the Philadelphia/ Eastern PA /S. Jersey area? |
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Coke-in-MN
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Joined: 12 Sep 2009
Location: Afton MN
Points: 41979
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Posted: 12 Mar 2022 at 4:07pm |
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Life lesson: If you’re being chased by a lion, you’re on a horse, to the left of you is a giraffe and on the right is a unicorn, what do you do? You stop drinking and get off the carousel.
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Les Kerf
Orange Level
Joined: 08 May 2020
Location: Idaho
Points: 1256
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Posted: 13 Mar 2022 at 8:52am |
 clark66 wrote:
Found the other posts related to the gear shifter repairs, ThanksDoes anyone happen to know any outfits that do track press work that would turn the pins and bushings in the Philadelphia/ Eastern PA /S. Jersey area? |
I thoroughly researched every post I could find on the shifter repair, then came up with a plan that fit my budget and needs (read that as looooooow budget and simple needs). A lathe would have certainly made the project quicker and easier, but probably not much more precise (I do have some experience with precision hand fitting of metal parts). My main concern is about longevity due to future wear at the interface of the new brass portion bearing upon the roll pin. I did position the roll pin with the smooth portion facing upward so as to have the weight of the shifter bearing on the largest surface area, and I did hand-pack the entire area with grease. So long as the roll pin does not break I do believe it will last longer than I will need it, and my grandson did observe the whole process, so he should be capable of completing the repair next time  Your pins/bushings need to be turned RIGHT NOW! Do not pass Go, do not collect $200
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clark66
Bronze Level
Joined: 29 Dec 2011
Location: south jersey
Points: 11
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Posted: 13 Mar 2022 at 5:00pm |
Right! looks like there right on the edge of wearing through, Thanks for the links to the shops- Its a shame they weren't turned before, it looks like the sprockets and pads barely have any wear and seem to have been replaced somewhat recently. 
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