Transnission shift shaft.

[Trailrider]

Will try to make thiis short. Took a muddy ride with my new Hammerhead shift lever. It bent like a pretzel in mud. The real problem is the shift shaft appears angled rearward but still shifts and does not leak.
What's the consession, if it ain't broke don't fix or a complete tear down. Can the gear shaft be replaced without complete disassemble? Any suggestions, I'm 56 and don't ride much or I would buy a new one. Please no jokes, I recently had a stroke and this was going to be part of my exercise, walking ariound the neighborhood is not my thing.
Help,
Trailrider



2001 XC300

[Catarallus]

My english is not good but i will try it.

- First you have to dumping the cooling water of the engine.
- Then cut off the shift shaft near the engine case.
- Lay down the motorcycle on the left site
- Take the right ( big ) engine-cover apart.
- Then you can pull out the shift shaft trough the enginge case.

[jostby]

As long as it isn't leaking oil you can leave it. If it's binding or the looks of it being crooked bug you it really isn't hard to replace. Like Catarallus said, you have to cut off the splined end as close to the case as possible, a clean cut, no torching it off. The bend will keep it from coming out. That's why you have to cut it off.
Pull the right side cover and for the most part it just slides right out. I don't remember if you have to remove the internal kickstart ratcheting gears. If you do, keep them matched for easy assembly.

[stevethebrit]

Don't you have to just remove right-side cover and the clutch basket? The kick gears shouldn't be in the way. Have done the same job on an YZ, but never an EC, so I could be mistaken.

[Catarallus]

The kick gear's have not to be removed. By the clutch basket i'm not sure.

[slocalspode]

Trailrider wrote:
"The real problem is the shift shaft appears angled rearward but
still shifts and does not leak."

Does it look like this?


A buddy of mine dropped my GG250 on a trail ride and bent my shift
shaft too.
I sent the motor to Smackover Racing, back when they were still around,
they replaced the shaft without having to split the cases.
It has been working great ever since.
Jeff, so. cal.

[jostby]

Dang, that sucker was really tweaked!!

No you don't have to split the main case.
Yes, you do have to remove both right side clutch covers (large and small). And that would include the water pump cover and draining the coolant.

[gasser]

The clutch basket does not have to be removed.

[iancp5]

It's pretty easy if it isn't bent very much. Remove the side case opposite side to shift lever. You remove a couple of pieces, can't remember exactly and knock the shaft through with a suitable SOFT drift.

If it's bent a lot this will damage the holes in cases that it operates through so not so easy you will have to cut the splined, bent end off first close to the seal or maybe inside the seal. Has to be a judgement call. But if it's not leaking and you can still change gear ok leave it.

[Trailrider]

SloCalSpode mine does not look anything like that. The splines are good, just a slight bend to the rear. It shifted and I rode it in with mangled shift lever.
I will try to get a pic or two, not very good at uploading pictures.
Time will tell, I picking up my shifters today, had him lenthen the stock one, may try that first.
Regards,
Jim