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Shifter shaft to a point that I need help pic

  • Thread starter Thread starter rombi
  • Start date Start date
R

rombi

Guest
OK so I have taken my sweet time to get this far but here I am. If any remember I bent my shift rod and I am trying to remove the bent one for a nice straight one. I am at this point and I see a few options but what is the best advice here.
It is a 82 gs650e.
 
GET the SHOP MANUAL! After that, replace the shaft by following the instructions in the manual. Good luck. You can do this but USE THE BOOK! LOL!! Ray.
 
Mr. rombi,

There is a 650G Suzuki Shop manual on my site. On the clutch side, it may be close enough to help you. There is also a link to online Clymer manuals on the "Greetings" page. Happy wrenching.


Thank you for your indulgence,

BassCliff
 
Cut off the gear shift shaft from the other side from the picture as close to the crankcase as possible. If you can make sure the bent part of the shaft has been cut away.

File down the portion where you have cut the shaft so the burrs do not damage the seal (personally I would put in a new seal) or the alloy crankcase where the shaft has to pull through. You will see what I mean when you start doing it. Remove washer and circlip on gear shift shaft from sprocket side of engine.

Go to the other side of the bike, where the picture was taken from. Remove bolt holding cam stopper. Take off spring and remove cam stopper. Disengage shifting pawl from upper part of gear shift shaft and remove shaft from engine.

Hope this helps. If you need more info please reply. I have just done this job on my 550, very similar setup, to split my crank cases.
 
What about the part that is welded on the shaft itself? I assume that a new shaft has that welded on it or am I missing something here????
 
That plate welded to the shift rod (shaft) is all one piece. Pull it all out towards you when the bent part of shaft on the other side is cut off. It should come straight out without much effort. A couple of springs come off and that's it. I took plenty of digital photos when pulling mine apart so I had a good reference if my memory failed me as it usually does (SENILITY I THINK THEY CALL IT).
 
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Ok I have everything that I need off I think. Just need to cut the shaft off close to the case. Once that is off I think I see the light. Maybe....
I do appreciate the help brothers.
 
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