View Full Version : How to: replace shift shaft?

12-19-2009, 04:44 PM
wondering how easy it is to replace the shaft that the shifter bolt to? Mine split apart in the recessed area?

I assume the right hand side case needs to come off along with the clutch basket. What else is involved or do I have it all wrong?


12-19-2009, 05:49 PM
time to split the cases my friend...right down the middle :p

12-19-2009, 06:45 PM
Good luck my friend.....I have been puttting mine off since the Steele Creek GNCC. I got a new shifter after that race. It lasted about 2 races. I used JB Weld, lasted 1 race. Then I finally welded the shifter to the shaft. Now time to break down and split the cases and replace the shaft before the start of next season......which is only 2 months away.

Let us know how everything goes...if you end up doing it yourself or sending it to someone. I am going to send mine to Moto-X-Perts so they can replace it.

12-19-2009, 06:48 PM
wow...your paying to ship it and fix it? how much do they charge? ill do it for ya if u wanna ship me the motor for half the cost of them...

12-19-2009, 08:25 PM
I have changed mine twice. BAD HONDA!!!!!

12-19-2009, 09:47 PM
just to make sure there is no confusion...I do mean on a 2001 400ex. I know my signature lists a 450r.

The 400ex is my trail quad.

I think I will opt for welding too until I have to tear the motor down.



12-20-2009, 09:54 AM
I am sponsored through them. I am just sending them the bottom end. They are going to do the ISF process on the gears also through CV4. They paid for shipping last time.

02-18-2010, 10:38 AM

Can you just remove the LEFT case including the stator and starter ?

Or do you HAVE to do both sides (including the clutch) to replace the shifter shaft ?

They show in the manual that you seperate the Left case from the right.....but if you're not removing the Transmission......why can't you leave the Clutch side alone ???

Anyone ever try this ? Or am I looking at a complete dissassembly ?


02-18-2010, 05:10 PM
You don't just remove one side of the case it splits and all the inners must be removed in order to get it to split. Its the same as what you would do to replace a crank for the most part, except you are replacing the shift shaft...

02-18-2010, 05:43 PM
I understand that part......It's just that in the HONDA Service manual it shows the right side (clutch side) being removed from the Left side Stator side)

So If I take the Clutch and gears out.....I can seperate the case halves WITHOUT removing the flywheel.


I just hate taking things apart or dissassembling things that aren't neccesary.

02-18-2010, 07:10 PM
Ah ok, I should have figured you knew that with those quads in your sig but you never know around here haha.

Sorry I cant help you more than that I havent looked that deep into this engine.

02-18-2010, 07:23 PM
Mine has been welded for the past year and it still holding up. No since in splitting the cases until you need to. The shaft is ruined anyway so just weld it in place. Be careful not to put too much heat on it. Rap a wet rag around the shaft while you weld on it. Have some water handy to cool it off. Weld a spot and then cool it off and then weld it some more, a little bit at a time. If you get it to hot you will melt the seal in the case and it will leak oil.

Good luck

02-18-2010, 07:46 PM
Yeah....I know my 250R like the back of my hand.....I'm just gettin' my feet wet with these 4-strokes.

I have to replace the shifter shaft as some "backyard butcher" welded it!!! I'll post some pics so you can all have a laugh.


I removed the 11 bolts on the left side going into the right case.....then removed the RIGHT cover....Clutch, crank shaft gears....didn't touch the OIL PUMP.

A couple wraps with the old hammer and VOILA!!!

She's apart.

Now I have to CUT the old shifter shaft and pass it through the case.

Thanks for the replies...guys


02-27-2010, 03:03 PM
Here's a pic of the Shifter shaft....Looks like he changed the oil with a pair of vise grips!!! That bolt is trashed!

02-28-2010, 10:52 AM
ive done mine once. and yes she ha to be tore down all the way. there is no way around it. face it bud that transmission and crankshaft will be looking at you before you get a new shaft in it

02-28-2010, 12:39 PM
Yep! This way I got to see the condition of EVERYTHING!!!

BUT! You only have to remove the CLUTCH Side cover and then split the cases....YOU DO NOT have to remove the Mag cover and Flywheel.

The Shift forks....gears and clutch were all really good! No gouges or chunks of metal missing anywhere.

I should have taken step by step picks and maybe had it posted as a Sticky!


02-28-2010, 12:46 PM
there is an easy way to prevent the shaft from stripping. just put your lever in a vice and grind it with an anglegrinder so it will crush tighter.

02-28-2010, 05:35 PM
my shift lever is starting to come loose and ill tighten it good but once i ride its loose again. what should i do?

02-28-2010, 08:32 PM
Originally posted by moddedblaster20
my shift lever is starting to come loose and ill tighten it good but once i ride its loose again. what should i do?

What the guy above says...grind a slighter bigger slot in it so it can tighten down better.

02-28-2010, 08:40 PM
ok man. i will try that one day! i just dont want to take everything apart to fix that. thanks