Gear Selector Shaft Bent?

[iancp5]

I finally worked out why I couldn't get my gear shifter in quite the right place - the selector shaft seems to be pointing down slightly!

Surely it can't be bent? It looks like pretty substantial steel and I would expect the shifter or the case to break if it received a hit big enough to bend the shaft? Thoughts?

I assume I'll need to completely strip the engine to fix this?
As it all appears to be working with no oil leaks I'm thinking I may as well do this season then do a complete overhaul. If I do a complete rebuild is there anything that should be automatically changed on the bottom end or is it a case of just checking for wear. Although with the sparse information in Gas Gas manuals how do you know if something's worn?

 

[slocalspode]

Does it look something like this?

or this?

It surprised me too, that the shaft bent without breaking the
lever or the cases. I did not seem to leak oil either.
It can be replaced without splitting the cases, or so I am told.
SmackOver Motorsports did the repairs for me.
Good luck, Jeff so. Cal.

 

[PEB]

I have bent one shaft and broke the weld on another. To replace the bent one you will need to cut it off flush with the case. The clutch side cover and clutch basket will need to be removed to get at the shaft. The tricky part with the bend is all the bend must be cut off or you will have to push the bend through the hole in the rear of the cases. Splitting the cases cannot be done untill the bent shaft is removed. If you are going to keep the bike I would replace the main bearings, crank bearings, tranny bearings, gaskets seals etc.

 

[iancp5]

Wow - Mine isn't bent that much!!

Looking at the parts fiche it looks like there is a separate bush and oil seal where the shaft passes through the case so I reckon it should not need cutting to remove as mine isn't that bent. It's just enough so that when the shifter is in the ideal position it hits the frame selecting first which means I sometimes can't select first.

Splitting the cases cannot be done untill the bent shaft is removed.

Does that mean if mine will push through I can change it without removing the engine and splitting? I just have to remove the clutch basket?

 

[GMP]

Yes, it should slide right through if straight enough. The oil seal can be changed from the outside as well. When you get the new shaft assembly, take the time to inspect the welded on stamped piece for burrs and irregularites that can cause the sliding "scorpion" to hang up. Run a fine file on all the sharp edges of both parts.

 

[PEB]

If you can see the bend it will not push out. Splitting the cases would come after removing the shaft. If you can get it out no need to split them unless you are servicing something in the bottom end.

 

[iancp5]

If you can see the bend it will not push out. Splitting the cases would come after removing the shaft. If you can get it out no need to split them unless you are servicing something in the bottom end.

It looks like a big hole in the case once the bush is pushed or pulled out?

 

[PEB]

The hole just a hair larger than the shift shaft. A bent shaft will not push through it. If the shaft is bent you will have to cut the bend off the protruding end and then press it through.

 

[blitz11]

Can you put a box end wrench on the shaft and bend it close to straight? This would work on my old honda sl100 (in the days before we had bendable shift tips). it might be worth a try.

Another trick is to get a piece of small diameter steel tubing, place it over the shift shaft, and try to bend it straight. Can't hurt to try this before you cut the end off.

blitz

 

[Loosenut]

He could also crack the case trying to bend it back. I would cut it off.

 

[iancp5]

He could also crack the case trying to bend it back. I would cut it off.

I agree. Despite the fact hitting something bent it I am certain if I try and bend it the case or something expensive will go.

But looking at the hole it looks easy big enough for the shaft to extract through. From the parts fiche there seems to be a large bush in the case and the seal inside the bush. I'm thinking if I hit the shaft it would knock the bush out with it?

 

[GMP]

I would not try and bend it in the case. If it doesn't come out after cutting the bend as flush to the case as you can get (and deburring it) try it from the other side. Remove the side cover and clutch, cover everything up good, and CAREFULLY dremel off the weld that holds the fork stamping piece to the shaft. Once this is off and the shaft cleaned up it should slide out the other way through the cases. It may take awhile but a lot less time than splitting the cases.