shifter stripped, fix?

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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ohgood
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shifter stripped, fix?

Post by ohgood »

the splines look bad and the shifter, not much better on the shaft.

is there a guide to replacing the shifter shaft?
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gsa102
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Re: shifter stripped, fix?

Post by gsa102 »

On most full size bikes you have to remove the clutch basket and the shift shaft pretty much just pulls out from behind it. Should have a spring to hold it in the neutral position that you will have to remove as well. Also a good time to change the seal.
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ohgood
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Re: shifter stripped, fix?

Post by ohgood »

gsa102 wrote:On most full size bikes you have to remove the clutch basket and the shift shaft pretty much just pulls out from behind it. Should have a spring to hold it in the neutral position that you will have to remove as well. Also a good time to change the seal.


man I hope so, going to check the parts fiche
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Tedh98
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Re: shifter stripped, fix?

Post by Tedh98 »

That it how it works on my H series.
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diymirage
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Re: shifter stripped, fix?

Post by diymirage »

A semi fix might be to take a grinder to the shifter and cut the opening out a little more, that way when you tighten the bolt it tightens up better
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
ohgood
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Re: shifter stripped, fix?

Post by ohgood »

diymirage wrote:A semi fix might be to take a grinder to the shifter and cut the opening out a little more, that way when you tighten the bolt it tightens up better
already did, and then tried red loctite on both the splines and bolt
JasonK94Z
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shifter stripped, fix?

Post by JasonK94Z »

The bike is worth the fix. Will make a nice project and maybe a good time for some other maintenance as well.
Just trying to put a positive spin on it for ya.
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newbbewb
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Re: shifter stripped, fix?

Post by newbbewb »

you CAN place a tack weld onto the very end of the shaft then move over to your shifter. you can either grind the weld off to get your shift lever back or just plasma cut the whole mess off when your ready to change the shift shaft. not recommended but it does work very well.
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diymirage
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Re: shifter stripped, fix?

Post by diymirage »

newbbewb wrote:you CAN place a tack weld onto the very end of the shaft then move over to your shifter.

don't let the mods see that advice, they will take one of your stars away :lol:
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
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