Hammerhead Designs: "Shift Tip" Offset and Vertically Adjustable Shift Lever
The stock KTM shifter has some problems: it's a little short for larger sized boots, it can't be rotated up one spline on the shifter shaft for toe extra clearance (without installing a 13T countershaft sprocket and filing the shifter arm for clearance) and it is sadly lacking in "bling". I needed a spare shifter in case I broke mine in the boonies, so I was really happy when Hammerhead finally offered their complete shifter assemblies for the RFS. Previously, you had to buy the tip and install it onto the OEM arm. They offer different offsets for increased overall length, and the tip has thick shims that can be rearranged to give a little vertical adjustment for fine tuning the fit. I initially ordered a +20 mm "Wide" tip shifter, but I quickly realized that was way too long for my size 45 (US 11.5) Sidi boots, so I re-ordered a +10 mm "Wide" shifter and sent the other back for a refund, with apologies. The cost is high at US$69.95, but being able to obtain the correct fit and having some small amount of adjustability is worth it. My old shifter is now my "trail spare".
The website has sizing information so you can pick the correct size for your boot... I guess I missed that page the first time. You can also choose a "Wide" tip, if you want to match the OEM size, or a "Short" tip if you want extra crash protection and a teeny bit less weight.
I also ordered the Hammerhead one piece shifter bolt/ washer with drilled head. I am a safety wire fan, and I had not yet wired my old shifter. The new bolt makes it easy to wire the shifter, which is pre-drilled near the hole. The bolt is $6.95 and comes with a cool shark logo.
The +10mm shifter, the free circlip, included in case
you lose or damage the one securing the pivot pin, and the drilled Hammerhead
bolt/ washer. There is no choice in colors. This is what you get for a KTM -
Hammerhead's Part number for this particular shifter is "KTM4SL+10W".
Top view.
Close-up of the tip showing how easy it is to adjust
vertically. Pop the circlip out, pull the pin, shift the washers around, and
reassemble. Simple, unless you lost some parts in the dirt....
The circlip. You need a pair of miniature circlip pliers to
remove it without damaging the part or having it fly off into the weeds!
The KTM shifter in the stock position (upper pic) and
raised one spline on the shaft (lower pic). I have been riding with the raised
shifter two years with no complaints, except that I can't fit a 14T or larger
front sprocket. Since I plan to go to a 14/50 combination soon, I needed to fix
this problem. As you can see from the tape measure, the raised shifter sits
almost exactly 1 inch higher than stock. However, raising the shifter also moves
the tip BACK approximately 0.25 inches.
Note!: The tape measure is for reference, and was not moved for any of the following pics. If you want to compare two different setups, simply open the two (same format) pics in new windows and toggle back and forth between them. It's kind of like a jerky movie... Also, the bike is resting flat on it's skidplate on a race stand, so everything is rotated back a little from the actual Real World riding position.
The Hammerhead +10mm Offset Tip Shifter in the stock
position (upper) and raised one spline (lower). Note that the increased length
has raised the tip in both positions, compared to the shorter KTM shifter.
The following two pics show the radically different boot angles you get, depending on the spline and shifter configuration. They illustrate why one will be comfortable and the other will be agony. The Hammerhead tip in all pics is in the stock (centered) position, and that is how I finally installed it. The boot is a size 45 (US 11.5) Sidi.
The KTM shifter in the stock position (left) and
raised one spline (right). Note in the right pic how far back the shift tip
rides on the shifter pad. The shifter is too short!
The Hammerhead Offset Tip Shifter in the stock
position (left) and raised one spline (right). Note the extra boot clearance due
to longer length, resulting in reduced angle. Also, in the right pic you can see
the tip nicely centered on the shifter pad of the boot.
Upshift comparison, gearshift at max upper travel:
the KTM shifter (upper) and the Hammerhead shifter (lower). Note the increased
clearance of the Hammerhead shifter, between the chain and shifter. I'm not SURE
the Hammerhead shifter will clear a 14T sprocket, but it might, with a little
filing. I hope so! More later...
After playing around with various positions (so I
could photograph the combinations), I cleaned the shaft and shifter with brake
cleaner, pre-wired a short amount of 032" stainless safety wire to the shifter
and mounted it on the shaft in the "+1 position". I then added blue Loctite to
the bolt threads, and installed and torqued it to 89 inch pounds. I then
finished safetying the bolt . The safety wire does NOT eliminate the need to
check the bolt periodically for tightness!
The old shifter now rides inside the airbox,
wire-tied next to a set of plastic KTM "emergency get home" bar levers from the
Hard Parts Catalog. I put the old shifter bolt and washers into my spares kit in
the tool bag.
Also visible in the above pic is a 48 inch length of 5/16" black automotive fuel hose for refueling other bikes on the trail when my bike is in its "KTM Valdez" mode. It slips nicely behind the rear fender side piece, and needs no securing. I can retrieve it in a few seconds if needed. The black cable with disconnect plug is the wire powering my electric vest - it runs up to my tank bag. When it warms up outside, I remove the front cable and use the rear connector to plug in the battery charger.
I have not yet ridden the bike with the new shifter. I'll post a follow-up in a month or two, after I have tweaked the adjustments.
Hammerhead Designs - Innovative Motorcycle Parts & Accessories Home Page
Why the Hammerhead Designs Shift Tip Article on why you need one.
Hammerhead Designs Products Product descriptions including sizing charts.
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Updated May 08, 2007 |