A 3D Printed Shift Lever

geder · Aug 21, 2023

I made a post a couple of days ago about trying to source a new shift lever for my 06 xbr12 after stupidly dropping it. In that down time I modeled up a replacement one so that I could try and print one with my printer and use it as a temp solution (possibly longer) or have one custom cnc'd. I've only ridden with it for about 30 miles now so it seems to be holding up well despite its rough looks. I can't upload the stl file so here's a link to the onshape document where you can download/export it. If you're going to print this yourself for some reason, I would use a higher temp plastic like ASA or PETG, however I printed mine in PLA and it seems to not get hot enough in the area it sits to matter currently. I'll try to remember to post an update in a month on how its holding up.

Cooter · Aug 21, 2023

100% infill? It won't like being outside, and frankly I'm surprised PLA lasted one up shift, lol.

Good luck buddy, keep vice grips with you at all times and report back what happens:up:

geder · Aug 22, 2023

25% with 6 walls compared to the default 2. More perimeter walls affects the strength more than the infill and helps keep print times and material costs low. I do agree that pla probably isn't going to hold up to the weather that well now that I think of it so I hope that ebay shifter comes soon lol. I'm off now to hunt down a charging system issue.

Cooter · Aug 22, 2023

Ya, same as tubing being more resistant to bending than solid stock but be gentle with that thing! Maybe shrink the homemade toe lever to reduce the twisting load too?

It's more than I'd ever ask from a 3-d printer, but good on ya for trying! I just put up the ol' Ender 3 (400X400) for a new dual extruder i-Fast to do more ABS work. Man tech has advanced!

geder · Sep 8, 2023

Update: after a long ride home from work a few days ago here in NC with outside air temps reaching near 98F, the shift lever finally started to fail and starting warping under load. It was solid enough to get me home but when I got to my apartment garage gate, the lever was toast and I had to use my hand to manually twist the linkage into first gear. It did surpass my expectations as it was only this extreme heat that lead to its demise. I think with a higher temp material like ABS or PTEG it would have survived even longer. None the less, I am very happy that the shifter I ordered came in just a day before this instance and was quickly back to normal operation.

Cooter · Sep 8, 2023

Wow! Thanks for the report, it lasted long juuust enough

Been messing with the new printer myself and used PLA with carbon fiber very successfully for some simple things like mirror block-off plates. VERY strong.

34nineteen · Sep 8, 2023

Is it possible to embed a piece of aluminum in the 3D printing? A lot of carbon fiber parts have been built with metal or foam cores in the bike industry.

geder · Sep 8, 2023

I've seen where people will stop the print half way and drop in a metal piece and resume the print to cover it up. It'd have to be modeled in but I'm not sure how tight the tolerances on something like that would be

A 3D Printed Shift Lever

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