Shift Shaft Spline Compatibility

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I want to graft a new spline onto a shift shaft with damaged splines (got 3 to do) and do it for less than the cost of a reproduction part.

Do any of you know of other bikes (preferably small commuters so parts are cheap) that have compatible splines to the XS 650.

I have been told Yamaha R1 and R6 are the same but would like some other options.
I hope to add this list.

Thanks
 
I can't speak for other bikes that use the same spline, but when I have had damaged splines on a bike and wanted to keep repair costs down I have had good luck with drilling the shaft and shifter where the splines meet in 3 different spots(pointing to the location in the first pic) and then tapping in roll pins to those spots they are usually about 1-3 bucks depending on size. Now the roll pins act as the splines It's not a perfect fix but probably the most cost effective
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Thanks DC and Two Many, after a bit of research it appears that all the Yamahas I checked had the same spline. Don't take this as gospel as had a very small sample size.
Even tried an XS gear lever on an AG 100 and it fitted. Thought fleetingly about going to a local farm bike wrecker but my guess is that the shafts on farm bikes would be flogged out worse than the ones I have.
So took a punt and ordered a new shaft for a YBR 125 from China US $22 delivered. It's probably made of cheese but will do. When it's done I will let you know how it worked out.
 
The YBR 125 shift shaft arrived, the XS gear lever fits. Although what I intend to do is not an original idea I will document the procedure.
 
Stepping through this:
The first problem with the YBR shaft is that it is 12mm and the XS shaft is 14mm.

To work around this a Glycodur Teflon lined bush (part no. PG 121425F) or EZI Glide bush (part no EZU01201425) can be used to reduce the size in the alternator cover guide hole from 14 to 12mm.

Measure the shift shaft from the collar to the end of the spline (260mm).

Grind off the weld and press the shaft out.

Cut off the old spline in the necked section of the shift shaft. Cut the new shaft roughly to length. Bore a hole in it. Turn a spigot on the old shaft that is a snug fit in the new shaft.

Check length, then press back together, weld.

Push bush in side cover it may need some retaining compound at it is pretty sloppy. It is not fully inserted in the photo.

Total cost $ NZ 25.63, cost of reproduction XS part $NZ 99 + shipping.
 

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