shifter shaft replacement (spline worn off)

eosdelb

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Hello everybody, I need to replace my shifter shaft. I looked at the Haynes book and really dont know any more than before. What I want to know is, Can you swap them out without splitting the case? It looks like you take the covers off both sides but I am not certain. If anyone has done this before I would appreciate their input.

Thanks
 
take the left and right engine covers off, can't remember if it is slightly behind the clutch or not, but no need to split the cases.
 
Thats good news. I got me a bendix repair kit to get that electric starter working too.
Thanks Jay!
 
Yeah, thanks Jay!
Bledsoe, keep us informed of the fix, I've a spare motor in need of a replacement too. I've got the replacement shaft and am interested in how you do.
Rick
 
I fixed mine by grinding the gap in the shifter pedal wider. This lets the bolt squeeze it slightly tighter on the shaft. Obviously it won't work if the splines are gone completely...but in my case it will do until my next engine rebuild.
 
Yes, both left and right side cases need to be removed. Drain oil before removing right side.. The clutch will also need to be removed ( need a clutch holding tool such as from Mikexs, or look in the "Tech" section under Tools. .......make one from an old clutch plate)

Remove a clip on the left side and it comes out from the right side. This is also an excellent time to replace the shifter shaft oil seal if needed.

Pay attention to the washers that you remove from the clutch, so that you can replace in the same order. Also check the washers etc. against a drawing as PO's have been known to leave out some parts:doh:
 
Quite often the shafts are bent. You might have to actually pound them out with a long punch.
 
Thanks everybody, one of these days, I will be able to answer some questions. All I can say is, "buy the most perfect bike you can". Now how you tell that I have no idea. I hope I get to ride it this weekend. I think I have hoped that before. :) It could happen though.
 
NJ1639 I must say everyone has been helpful but the retired gentleman laid it out there flat for us. If Haynes manuals were worded like that they wouldnt need pictures.
 
An easy fix: Poistion the shift lever where you want it, clamp it down with the original mounting bolt and cross drill (about 1/4") through the lever and shaft and put a bolt in.
 
That is exactly the way mine was "fixed" by the PO and it broke off in the center of the hole that he drilled in the shaft.
I just hate to find myself on the side of the road somewhere wishing I had done something right, or never going anywhere because it might break down. It might be next spring when I get to ride, but when I ride I wont be scared to take it anywhere.
 
Drill it so the hole only dimples the shaft and put in a set screw. You may use 2 or 3 srews. I would use lock tite on the set screws. By not drilling through the shaft you should not do any harm to its integrity. Tony C.
 
One vote for replacement of the bad shiftshaft for one with good splines etc. Think of how many times a year you have that left side cover off for one reason or another? As well for retaining the ability to change the position of the pedal lever on the splines. It's really not a big job and TRG's instructions are spot on (as usual). Changing the seals at the same time if needed makes sense as well. All in all... a good little "getting to know you" project that's not bad to get at or do.

Note: make sure you put a pedal lever with good clean and clear splines and assure that they fit well together (shaft & lever) before the shaft is installed and buttoned up and the last thing you try to is fit the old lever over the replacement shaft. Buggered up shafts cause buggered up levers don't ya know?

Need not guess how I came upon that conclusion. Best, Blue :thumbsup:

My all time 'bandaid' solutions.....drilled through and cotter pinned..... small vice grips as a temporary lever clamped on the ex splines of the shift shaft.
 
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If you are mechanically challenged as I am and in need of shift shaft removal and
replacement info send me a message I will break it down step by step.
 
Shift Shafted in California. While adjusting the gear selector arm on my shift shaft
I noticed it was not grabbing the gear selector star. I removed the shift shaft and bent
the gear selector towards the case about 2 mm. Now im shifting through all gears properly. I hope this tidbit can help somebody. sometimes manufacturing errors may
occur. Stop me if im misinforming the xs community.
 
I have welded them on lightly on the outer face. Never had one break and it's a 10 second job to face the weld off with a side grinder in the future if you need to remove it. No harm if it needs replaced anyway.
 
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