Gear Shift Spindle

[Richardhamiltonfox]

Hi Everyone,

The small splines on my gear shift spindle (the shaft that enters the crankcase) are worn out.
The lever is fine and currently attached with epoxy metal compound which works ok but is not a reliable/permanent fix and requires gentle footwork.
I have a replacement spindle.

Can anyone advise me on changing a gear shift spindle?

Is it an 'engine out' procedure?
Or can it be carried out with the engine in place?

Any tips would be gratefully received.

Thanks

[Mezo]

Engine split.

This is Geoffs latest engine rebuild he`s doing right now, you can see the lever.



Mez.

[jibber]

Yeh, engine out and total strip, and then you run into replacing what ever else you find when your in there. If your happy with the motor otherwise (what sort of mileage is on it ?) and not worried about a bodge, a couple of tack welds might do you ??

[kevingrahambutler]

I did the same on my ttr 250 stripped the cog, so I did a fix by drilling straight through the lever and cog and put a pin through, using some metal weld putty it lasted two years then I sold the bike, I used the bike for off road trail riding so it did take some pounding

[steveloomis]

In my experience the shift lever is not tightened enough at some point where vibration and usage causes it to wear. I would try a new shifter lever, tighten well and see how it feels. You may still have to replace the shaft but at least you will be new all the way. Welding or drilling is a poor fix and only applicable in an emergency in my opinion. One thing I've done is to hammer the shifter lever tighter where it slips over the shaft, again this is a temp fix unless it really tightens up and does NOT move on the shaft.

[kevingrahambutler]

If you are planing to keep the bike I would say yes it's a temp solution, if you want to keep using the bike this would be a option, there is other methods not as brutal that would get you by but either way they are all temp fix, the cost of cracking the engine is not cheap

[Richardhamiltonfox]

Mezo, Jibber, KGB, Steveloomis,

Many thanks for this great insight.
Now I know the options I can decide what to do.
As it's a spare bike and not the one I use for long distances I think I'll let it ride.
Literally!

Thanks for your generosity.

Richard

[GeoffD]

Richard

What I would do is..... open up the gap in the gear lever so when you tighten up the pinch bolt it'll clamp down on the shaft...

[Windmill John]

As Geoff says. I've done this on two bikes. On one I hacksawed a mm or so off the gap, on the other bike, I popped an angle grinder blade in the slot to widen it.
Then I used a slightly longer pinch bolt, which once tightened, I put a nut on the other end and clamped it down, that stops the pinch bolt from slightly undoing.