Bent shifter shaft???????

[lonetree]

hi folks,
so im trying to rebuild my ec250, but i have discovered that the shifter shaft is bent, just out side the engine on the shifter side.
i was hoping that removing the nylon bush on the clutch side would free up the shaft enough to remove it, but it dosent...
can anyone tell me if the shift shaft is run through bushes cast into the cases?
if so i may have to cut the outside end off in a hope to remove it...
any advice? suggestions?

[Cruiser]

push it in from the clutch side as far as you can then cut the bent part off.. best option at this point. I've done this twice on my 97 gas gas..

[savage sausage]

as steve says cut it off, then undo clutch housing covers inner & outer remove the clutch and then you can fit a new one.

this Is what I have just had to do

[lonetree]

thanks guys.
got it out, hacksaw and a file to clean it up.

[FDB]

This is bad news.
Mine is bent too.
Was hoping for another solution but i don't think its going to be possible.
Also.
I see it bends easily if the chain comes off.
Will have to see if i can make a plan to keep the chain rolling past the shaft if it comes off again. Maybe some slider.

[Zman]

I would start by figuring out why your chain is coming off? Did the master link come apart?

[MNKeith]

Wow, thought this was a fluke but apparently not. I discovered mine was bent when I did the bottom end last year. Couldn?t figure out why it was such a bitch to put back together until I had the realization. Also was the culprit of my shift lever having more play than it should have. Good news was an earlier year was the same part # and it was cheap/available on ebay.

[FDB]

Originally Posted by Zman

I would start by figuring out why your chain is coming off? Did the master link come apart?

It came off because there was a section in the rocks where my rear wheel fit snug between two rocks. The one on the left had a peak sticking out that press right against the chainguide pushing the chain off the rear sprocket.
See 2:50.
https://youtu.be/XWNGngIJNu8

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