KDXRIDER.NET

My shift lever is just where it won't stay tight anymore. Tighten it it all the way and it's still a little loose. I believe I let the shift shaft and splines get worn.

Found a write up on how to replace it from the clutch side.
Doesn't seem too bad.

SHould I replace anything else while I'm in there?

13161 is what I need, correct?

http://www.motosport.com/dirtbike/oem-p ... -MECHANISM

I would think hard about a new seal for the shift shaft. You'll have the clutch off the bike, so if your plates are getting worn, now is a good time to replace them. You can also check the needle bearing on the transmission output shaft. If it's worn, it's an easy replacement at this time, too. Might consider your water pump seal, since the coolant is drained and the inner clutch cover is off.

That said, if all is well with the bike, I would probably just do the shift shaft.

When you say output bearings, are you talking about part # 92046 ?

http://www.motosport.com/dirtbike/oem-p ... ANSMISSION

And for the shift shaft seal....how do you get it out? Punch nit out from the inside, like wheel bearings?

Yes, that's the bearing I was talking about. It's replacible with just a pair of circlip pliers. For the seal, I use a cheaper automotive seal remover tool to pry it out. You can do it with a screwdriver with some difficulty and risk of gouging up the case around the seal, but I much prefer the special tool. It just peels the thing out in two seconds with no drama.

http://www.harborfreight.com/seal-puller-35556.html

pay attention how 92152 goes in

I somehow put that fucker on backwards and it took me 5 quarts of oil to figure out what the problem was

I did a search on shifter shaft and got 60 pages to look through.

Do you have the link for the write-up handy?

Thanks

http://kdxrider.net/forums/viewtopic.ph ... utch+cover

It's not exactly a step-by-step pictorial, but it's good information.

Good luck.

HA....that's exactly the thread I was about to quote.

Thanks Dfeckel . . . .

Thanks, I remember reading that thread but unfortunately didn't bookmark it. I'll probably be doing the proceedure over the winter and this will help greatly.

Yea, this time I'm going to locktight the shift lever on there after I get the new shaft on. Hopefully that will help long term.

ihatefalling wrote:Yea, this time I'm going to locktight the shift lever on there after I get the new shaft on. Hopefully that will help long term.

Go easy on the locktight. That small of a bolt might break when you need to remove it later. Try, I think it is 222 it is made for small screws that will need to be removed at a later date.

OK....thanks for the heads up. I have had bolts break b/c of locktight before. Thx....