Gear lever circlip groove wear?

[Clem2112]

For the second time since the bike's rebuild the circlip parted company with the shaft today.
Just made it down a slip road in second luckily.
I may have used a non standard circlip burpt it looks like the groove in the shaft is a bit shallow?
Anyone here come up with a better way to retain the lever in this setup?

[Nurse Julie]

I had exactly the same thing happen last summer on my 400/4, half way around quite a fast corner !!. Put a standard size circlip back on and fingers crossed, hasn't come adrift again. But, like you say, the groove does seem very shallow.

[mike the bike]

I cut the groove deeper with a hacksaw, it hasn't fallen off since.

[Clem2112]

That idea crossed my mind too , after a beer !
It would be a really tricky job to re plunge cut the groove on a lathe after all.
Cheers.

[PatM]

Easier that stripping it off to mount it on a lathe! Dremel might assist, but junior hacksaw would be kinder and easier- less chance of going too far!

[mike the bike]

I had a closer look at mine; It's been a while since I modified it but I drilled through the shaft and fitted a split pin.

[Clem2112]

I guess a washer and split pin or R clip would be option 2.
 First find a sharp 1.5 mm drill

[Clem2112]

Drilled it. Stainless washer fettled to fit the pivot and retained with a split pin.
I defy it to fail again !

[Nurse Julie]

I think I should do the same modification sometime, it's really not a nice feeling when you go to change gear and there is nothing to change gear with !!!