Shimano R-9160 TT/Tri Shifter Button Repair

Repair your broken Shimano r9160 bar end TT shifter for your tri or TT bike. I had a customer with both buttons break while shipping the bike and we had to replace them both. Customer gave me the shifters and after taking it apart, i was able to make a glue in replacement seat for the rocker pin of the shifter button. The ears come off the shifter body that hold the 1mm rod in place. These ears are very small and weak. This design is significantly more robust and utilizes the existing geometry of the shifter to hold the replacement seat.

I recommend using a very small dab of glue on the seat not only on the body where it goes into the shifter but also on the metal rod to hold it in place. It can of course be used without the glue on the rod or even on the body but it can certainly fall off. I decided against the enclosed ear since the printer would likely have a hard time making a 1mm hole with such thin walls, having the open top makes it easier to print and it can be installed with zero modifications. 

All my prints have been in PLA so adjust if you wish to use something like ABS where shrinkage may be an issue. I think for a light duty application like this, PLA should be fine but PETG or ABS are probably safer bets since it is a functional piece.  Printed at 0.08, infill does not matter since its so small. Print on the side laying down or vertical, both seem to work fine. 

I have 2 versions on here, V2 is a straight grove and is shown as the blue model in the pictures. Works great, has a good snap in. V3 has a slightly smaller mouth in the hopes of it clicking in even better. This offers a better hold but pretty much no click like i was hoping. They work way better than i was hoping and i think its more a limit of the printer and size of extrusion than design so i am very happy.   

Uploaded the files as step files to maintain quality but also if adjustments are needed. Very fast print, less than 12 mins on my P1S and 0.28g.