Gear shifter jaw jig (Babetta 210)

 I have prepared a 3D model of a jig for adjusting the gear shifter jaws of the Babetta 210 moped. 

Material PLA+, infil 30%. To complete the jig, you will need 2 pieces of round beam diameter of 8mm and a length of 40mm and an M8x40mm screw with a nut M8. 

You can buy a huge number of replacement jaws on the market. But they have one common problem. They almost do not fit at all and can only be installed after a lot of effort and modifications. Most of these jaws are deformed and have slightly different dimensions. The easiest way not to waste money on low-quality components from Asia is to use original jaws.

 You need to remove the badly worn friction lining from them and stick new ones. A strip of new friction lining can be purchased, for example, in stores selling car or tractor parts. I use a lining strip for the Zetor tractor handbrake. 

Glue the lining with a two-component composite adhesive. Cut the lining larger than necessary. Hold the lining with clamps while gluing. After the adhesive has hardened, use a file to align the side edges of the lining according to the shape of the jaw. Then insert the jaw into the jig. Use the lower adjustment screw to adjust the position of the jaw and lining so that it exceeds the contour on the jig. Insert the side part of the jig and secure it with an M8 screw. Secure the jaw in position with the upper locking screw. 

Use a file to align the front and rear edges of the lining according to the jig. Then use a file to align the upper surface according to the shape. Then use a file to shape the contact surface of the jaw according to the jig. 

Adjust the second jaw using the same procedure. Be careful not to loosen the lower adjustment screw when replacing the jaw. Only loosen the upper locking screw.