Bent shift shaft

[Balaz_73*00]

So I was out riding today, my front sprocket came off. Wedged up in there nice and bent my shift shaft. Do the cases need to be split? Im mechanically inclined but never do my motor work. Is this hard to change?

[Scro]

No, it will come out by just removing the right side case cover. Granted, it's not bent to the point it won't slide out. If that's the case, you may have to cut it first.

[Balaz_73*00]

Its toast, I was already planning on having to cut it. Thats good news tho! I washed it and put it away in disgust. I couldnt see behind my moose poly case saver, Its so bent im kind of worried it might have even cracked the case. Ill have to see once I get the sprocket unwedged and the shaft cut to get the case save off.

[Scro]

If it's bent that bad, it probably is broke the center case at the bottom section where the shaft goes. It has happened to me before. I tried to fix it, but since that's the lip where the seal sits, it leaked. So I ended up replacing the case. Hope this is not the case for you.

[Balaz_73*00]

There was some oil sitting on my skid plate so it prob did crack it. This was only my third ride of the year on my fresh mxp built motor. Bummer. Im prob gona try to fix it myself, so I will likely be looking to you guys for advice

[Scro]

Buy a manual, or you can download it online with enough searching. It helps a ton.

[d3ktrix]

Heres the 05 TRX service manual if u need it.

http://shared.sploitz.com/05trx450rSM.zip

[Balaz_73*00]

d3ktrix- downloaded the manual, thanks!

Did some work today, it looks like the case survived. Oil was leaking because the seal was pinched so bad. I was able to click it in neutral but the shifting felt stiff. I imagine its because its bent. Overall, Im feeling pretty good after seeing this.

[fastredrider44]

You got lucky. All you will have to do is pull the clutch cover. I'm like scro, I've busted cases before.

[Balaz_73*00]

Im a little confused, Im at work so havent really dug through the manual but how does the shaft just slide out? Seems like 19,25, and 28 would hold or effect it from just slipping out?

[Balaz_73*00]

1

[Balaz_73*00]

I feel like im missing 3 and 35. Are those all exteral? 36 seems to be that big seal around the shaft. Does it make sense that 3 and 35 could have come off when the sprocket came off?

[d3ktrix]

Originally posted by Balaz_73*00
Im a little confused, Im at work so havent really dug through the manual but how does the shaft just slide out? Seems like 19,25, and 28 would hold or effect it from just slipping out?

Those actually slide all the way onto the shifter shaft and reside on the right side of the engine.
Only thing that is attached to the left end of the shifter shaft its the shift lever it self.

[d3ktrix]

Originally posted by Balaz_73*00
I feel like im missing 3 and 35. Are those all exteral? 36 seems to be that big seal around the shaft. Does it make sense that 3 and 35 could have come off when the sprocket came off?

IIRC 3 and 35 can come off from the outside of the case, so yes they could be missing.

[fastredrider44]

As far as the shift shaft coming out, as soon as you pull your clutch cover, you will see all those parts on that end of the shaft, so yes, it will slide right out.

[Balaz_73*00]

Thanks for the replys guys. Does the clutch basket need to be pulled? Also, do gou guys think I can do this repair with the motor still in the frame?

[krause19]

no and yes you can but it can be a pain i like to tilt the bike up a little with car ramps under the right 2 tires. Its really no to hard at all good luck man.

[Balaz_73*00]

Well I just ordered everything I think I need. I didn't order 19,25,or 28 in the first pic. I hope they are reusable? I guess I'll keep everyone updated on this as it progresses.

[d3ktrix]

Yeah those are all reusable.

[Scro]

I'd say you were pretty lucky. Mine didn't bend half that bad when it broke the case.

[d3ktrix]

I'm thinking its that moose polly case saver that saved it.
By the looks of the picture the shifter shalf only bent where it was extended out of the case saver, not at the case it self.

[Balaz_73*00]

I think the case saver helped too. Could have been alot worse

[Balaz_73*00]

All parts are in, should have some updates soon!

[Balaz_73*00]

One guy said the shaft will come out without pulling the basket. Is this true. Doesnt seem like it will. Also, the shaft is bent all the way up to the case. How much space is there within the cases. I dono if im explaining well enough, but basically will a bent shaft slide through the case or does it have to be perfectly straight?

[eastside 400]

on the 04-05 bikes the shaft will not come out unless the clutch basket it out. the 06+ bikes you can take the shaft out without touching the basket. If the shaft is bent you will probably have to cut it off where it comes out of the cases, its a pretty tight fit and any kind of visible bend will probably keep it from coming out

[Balaz_73*00]

Right on thanks. Any good home mechanic ways of holding the basket/hub from turning to break the nut loose?

[d3ktrix]

I made my own clutch tool by taking 1 old fiber and 1 old steel clutch plate and riviting them together.
Slide it into the basket and nothing will move.

For taking it off u can just use an impact gun. Need a tool to put it back on with the torque wrench though.

[Balaz_73*00]

Well finally got this done over the weekend. I'll post some pics of what I had to do to get the shaft out. Went pretty smooth. I did end up having to pull the motor to have room to cut the shaft flush with the case. I was buttoning it up putting the pressure plate with an impact and boom, sheared the head of one of the bolts off. So I have to get that out. I was rushing to wrap it up and did that. Smh

[fastredrider44]

Those clutch bolts get fatigued. Pull the hub out, drop a BB in the bottom side and thread another bolt from the backside. It'll spin the broken bolt out.

[Balaz_73*00]

I'll be shocked if that works! lol Thanks for the tip

[mikey726]

I broke one of my pressure plate bolts recently too, and i went to autozone and bought a set of reverse drill bits to get it out. I thought i would have to drill it till the bit caught, but it grabbed the broken end and spun it right out.

[fastredrider44]

That's another thing, you can drill with a regular bit from the backside. But I like the whole BB thing. It's really fast and no looking around for drill bits.

[Balaz_73*00]

What I started with

[Balaz_73*00]

As much as I could cut in the frame

[Balaz_73*00]

basket out

[Balaz_73*00]

It was bent all the way to where it went in the motor so I had to drill out as much as I could to get it straight enough to come out. This did the trick. My drill bit jumped and took a piece out where the seal goes. I filled it in with Jb weld (can't believe im using that crap) so well see if it works.

[300ex_#387]

You might not have to use any JB weld. Try using the seal and see if it leaks first. You may not have to mess with it.

[mikey726]

Originally posted by fastredrider44
That's another thing, you can drill with a regular bit from the backside. But I like the whole BB thing. It's really fast and no looking around for drill bits.
I never noticed that the holes went all the way through the hub. Those are both good ideas.

[fastredrider44]

I'm pretty good at breaking those bolts.:mad: I started putting new bolts in everytime I took it apart.

[Balaz_73*00]

Well I'll be damned, that worked perfectly 44. I actually just threaded the new bolt in on top of the broken one and it pushed right out. Good stuff

[Balaz_73*00]

Went out riding yesterday, everything worked flawlessing. Ill get one last pic in.

On a side note, if anyone wants to buy the old moose poly saver I had, ill let it go fairly cheap. Nothing wrong with it other than the one whole where the shift shaft goes through is a little egged out. Im anal and had to get a new one for that reason.

[400exBRAAP]

Sorry to dig up and old post fellas.
.Hey balaz can you type up a parts list of the things you ordered when you replaced your shift shaft. I can't figure out what part # is the seal for the shaft.

[Rich250RRacer]

Sorry to dig up and old post fellas.
.Hey balaz can you type up a parts list of the things you ordered when you replaced your shift shaft. I can't figure out what part # is the seal for the shaft.

04-14 seal 91203-KA4-771

It's on the center case diagram, not the one with the shift shaft.