Stripped Gear Shifter

[dooner17]

My gear shifter and the shaft are stripped. It won't take a bite at all anymore. Should I remove the shaft and the shifter and have them redone or weld it? I donno what to do it just sucks not being able to ride it. Oh and its a 200s.

[chris200x]

I have a similar problem only it is my sprocket shaft that is stripped. I was going to take the easy way out also and weld it. but the folks on here convinced me otherwise. you just make for harder work down the road. take the time and do it properly now or you'll be in for a bigger headache later.

[Oldshell4481]

i wouldnt ever weld anything that might need to be replaced later on, we welded my exhaust, and i might repair a frame

[MTS]

for a temp fix you can tack weld it on...just make sure its esaily ground off so when you get a new shift shaft or shifter(which ever is stripped) you can grind the tac weld off and put the new stuff in without wrecking stuff

[chris200x]

Yea then the tack decides to break when your 10 miles out in the middle of nowhere...fix it right!!!

[Tri-ZNate]

OR drill a hole throught the shifter and shaft, tap it, and put a bolt throught it. About $.20 you can be riding again.

[Oldshell4481]

lol thats why you bring vice grips and clamp on to er for emergeny shifting

[chris200x]

lol thats why you bring vice grips and clamp on to er for emergeny shifting


lmao...I did that one time. When I reached down to shift I hit a rock or something and my teeth bounched off the handlebars!!! :D

[honda200]

you can get axle repair stuff, its like JB weld, but not really, we did it to a set of rear hubs on a 300EX of my friends, works great, all you do is mix the contents together, and smear it onto the end of the shift shaft, and put the shifter back on in place, DONT tighten the shifter yet, wait 24 hours, then tighten it, you wont have any problems for a long time

and when you do have to replace it (later on down the road) all you have to do is loosen the bolt, and just twist the shifter up and down and it will slide off, and the axle repair stuff withh come off with sand paper

Curtis

[grundlegrabber]

Get a new shifter and shift shaft, do it right and don't ever worry about it again. Shift shaft not difficult to replace, only requires removing clutch cover. New shaft is probably a bit pricey but I'll bet there are plenty of good used ones out there.

[85200x]

The shifter got stripped on our 110 and we just took a hacksaw and cut the grooves deeper it worked

[jeswinehart]

OR drill a hole throught the shifter and shaft, tap it, and put a bolt throught it. About $.20 you can be riding again.

i would hop on that idea in a heart beat rather then taking the whole stinking motor out and tear it to peices. i don't think i'd do the tap and die work ,,, just a slip pin would be fine imo.

yep ,,, untill the motor needed pulled for some real internal issues i personally would go that route

john

[dooner17]

Ok I drilled a hole but it didnt work that well. Its still loose and requires pushing the shifter further than usual. Both the shifter and the shaft are stripped because a 4-wheeler backed into me. I'd rather weld it but the axle repair stuff sounds like the best idea. Where could I get that like canadian tire? Thanks for all the help

[LaDano]

I've got a extra shift shaft laying around when you need it.

[bigb9582]

just go to any atv/bike shop/dealer and order a universal one for $13.00. i had to buy one for my 200s when i still owned it and it worked great. the new owner still uses it with no problems. i think the dealer ordered it from PARTSUNLIMITED.

[mbubbac]

what i would do is line it up real good, drill a hole through the shifter and the shaft, get a high strength bolt with lock washers and a nut tighten that mofo down and * will be done and wha * only spent 20 cents and not 5 dollars on electricity for welding or 20 bucks on a new shifter F that

[dooner17]

yeah but i can't drill a very big hole or it will weaken the shaft so im limited to a smaller bolt. i guess ill drill as big as i think it can be and try to find a bolt

[mbubbac]

wait before you drill the hole get a good bolt first and get a drill the is the same exact size of the bolt so the bolt fits nice and snug and tight in there so * dont have any play or it would annoy the hell outa *

[dooner17]

yeah i already drilled a small hole and put a nail through it so i could ride it for the day. It had tons of play. Now I'm going to make the hole the same size as the bolt i got and tighten it up.

[chris200x]

Not to harp but if you would of taken the time and fixed it properly you would be riding right now with no problems. just my .02

[mbubbac]

yeah but whats the difference between drilling a hole putting a bolt throught and saving 20 bucks or so rasther than spending 20 and getting a new 1, wuts the difference and anway if * want to remove it which * dont do it all the time * still need to loosen the bolt on a new 1 anyway

[chris200x]

Just thinking of past experiences with my 250sx. The shaft stripped, I tried welding it but I guess I did not clean it good enough or something because it did not hold very long. Then I thought up the whole drilling a hole through the shifter and shaft. It worked but there was so much play in the shifter I did not care for it. So I ended up replacing it. It is not that difficult a job. What it was was just tryin to stall the inevitable. doin it right.

[dooner17]

ok well ive already drilled a small hole so ill try the bigger one and maybe try to get some axle repair.

[dooner17]

today after school I worked on it for a couple hours. First tried filing but it didn't work. I drilled the hole bigger breaking a couple bits. Than I didn't have a bolt small enough. I figured if I made a tempered pin out of a bolt it would go in tight with no play. I grinded a bolt and hammeered it in the hole really tight. Than I put the other bolt on and went for a ride. It turned out perfect. No play and it went it hard so it shouldnt come out anytime soon.

[Billy Golightly]

For future references, Take the shifter off the shaft. Take a hacksaw, and cut the gap out on the shifter wider that is used to allow it to squeeze on the shaft. Cut approx 1/16th of an inch out of the gap so it is wider. Get a GOOD bolt to go in there. Put it on the shaft and tighten the ever loving hell out of it. More then likely even if the splines are smooth it will still hold as long as you dont jump on it.

[dooner17]

oh i didnt really understand that

[Billy Golightly]

You didn't understand my directions?

[dooner17]

no not really