Is this shift shaft damaged?

indr · 01-04-2013, 09:03 AM

This is where the shift arms are riveted:

And there is enough play in the riveted area that the "shift mechanism arm" (left) and the "over shift limiter arm" (right) can easily overlap.

But they usually don't.

Neither of the arms look deformed or bent in any way. It's just that there is too much play where they are riveted.

Replace it?

ttpete · 01-04-2013, 11:39 AM

You should be able to peen the rivet over and take up the side play. Lay it on a flat metal surface and use the ball end of a ball pein hammer. Use light strokes and check the play frequently. Stop when it's tight enough that the hooks can't overlap but are still free to move easily.

sailah · 01-04-2013, 03:42 PM

Quote:

Originally Posted by ttpete

You should be able to peen the rivet over and take up the side play. Lay it on a flat metal surface and use the ball end of a ball pein hammer. Use light strokes and check the play frequently. Stop when it's tight enough that the hooks can't overlap but are still free to move easily.

What he said

indr · 01-04-2013, 03:51 PM

Will do.

concours · 01-04-2013, 05:36 PM

May be fine, does the shift drum have nice disc shaped sides that serve to keep these arms in place? That loose fit may be THE DESIGN to assure no binding. How did we come to have this apart? Symptoms? Just noticed it on the way by? SpringS OK?

bwringer · 01-05-2013, 09:55 AM

It's supposed to be that way. There are other pieces that keep the arms where they're supposed to be when in use.

Please don't go banging on it with a hammer.

The shifty bits in a Suzuki GS500 (and many other bikes) look a lot like that, and basically there's a plate over the end of the shift drum that keeps the "hooks" at the end in the right place. The side-to-side play is of no consequence, and some play is needed to ensure the assembly moves freely under load.

Also, you have omitted some VERY important information, like what sort of machine you're working on and whether you are having any other problems that would lead you to suspect this part.

indr · 01-05-2013, 11:38 AM

The bike is a 2010 Ex250. I'm assuming this could be damage because I have laid the bike down towards the shifter side more than once. Damage that could have transferred to what I see now. Also, I have tried to split the crankcase without taking out the clutch basket (stupid me) that might have put undue stress on the parts mentioned.

You and concours are right in that there IS a plate/disc that keeps these apart and in normal operation, there is 0.00001% chance of these two coming undone from their places and hooking up like in 3rd picture. I am just worried about the loosness.

All in all, I see no damage to the riveted area that would lead me to believe that they could have gotten that way because my mistake while trying to split the case.

concours · 01-05-2013, 02:48 PM

Quote:

Originally Posted by indr

The bike is a 2010 Ex250. I'm assuming this could be damage because I have laid the bike down towards the shifter side more than once. Damage that could have transferred to what I see now. Also, I have tried to split the crankcase without taking out the clutch basket (stupid me) that might have put undue stress on the parts mentioned.

You and concours are right in that there IS a plate/disc that keeps these apart and in normal operation, there is 0.00001% chance of these two coming undone from their places and hooking up like in 3rd picture. I am just worried about the loosness.

All in all, I see no damage to the riveted area that would lead me to believe that they could have gotten that way because my mistake while trying to split the case.

Put down the tools... back away slowly.....

Get a FACTORY shop manual, and begin reading.

Beezer · 01-05-2013, 02:59 PM

pretty sure the 2 arms are on opposite sides of the shifter drum... they can never touch when assembled. they also prolly ride in a track to keep them in alignment & have springs so they follow the shifter cam on the drum

indr · 01-05-2013, 03:03 PM

Quote:

Originally Posted by concours

Put down the tools... back away slowly.....

Get a FACTORY shop manual, and begin reading.

It doesn't answer my question.

concours · 01-05-2013, 07:04 PM

Quote:

Originally Posted by indr

It doesn't answer my question.

No, but it would have guided you through dismantling the cases properly. Does the bike shift poorly?

indr · 01-05-2013, 07:10 PM

It shifted perfectly about a year ago before I started dismantling it slowly. The reason for spliting the case is totally different. I didn't look through the manual before trying to do pry it open. I'll stick with the way it is and replace the arm spring. Should be okay.

01-04-2013, 09:03 AM	#1
indr ^OP Studly Adventurer Joined: Feb 2010 Location: BC Oddometer: 840	Is this shift shaft damaged? This is where the shift arms are riveted: And there is enough play in the riveted area that the "shift mechanism arm" (left) and the "over shift limiter arm" (right) can easily overlap. But they usually don't. Neither of the arms look deformed or bent in any way. It's just that there is too much play where they are riveted. Replace it?

01-04-2013, 11:39 AM	#2
ttpete Rectum Non Bustibus Joined: May 2009 Location: Dearborn, MI Oddometer: 3,537	You should be able to peen the rivet over and take up the side play. Lay it on a flat metal surface and use the ball end of a ball pein hammer. Use light strokes and check the play frequently. Stop when it's tight enough that the hooks can't overlap but are still free to move easily. __________________ 10 Ducati 1098 Streetfighter S - "Sleipnir" 09 Kaw Versys "The problem with Socialism is that you eventually run out of other people's money" _____ Margaret Thatcher

01-04-2013, 05:36 PM	#5
concours WFO for 41 years Joined: Dec 2008 Location: Kensington, NH USA Oddometer: 3,995	May be fine, does the shift drum have nice disc shaped sides that serve to keep these arms in place? That loose fit may be THE DESIGN to assure no binding. How did we come to have this apart? Symptoms? Just noticed it on the way by? SpringS OK? __________________ Too much is just barely enough..... 2007 Tiger 1050 2005 Royal Star Tour DeLuxe 1973 Yamaha TX750 1974 Norton 850 Commando Roadster concours screwed with this post 01-04-2013 at 05:42 PM

01-05-2013, 09:55 AM	#6
bwringer Gimpy, Yet Alacritous Joined: Jan 2008 Location: Indianapolis Oddometer: 1,723	It's supposed to be that way. There are other pieces that keep the arms where they're supposed to be when in use. Please don't go banging on it with a hammer. The shifty bits in a Suzuki GS500 (and many other bikes) look a lot like that, and basically there's a plate over the end of the shift drum that keeps the "hooks" at the end in the right place. The side-to-side play is of no consequence, and some play is needed to ensure the assembly moves freely under load. Also, you have omitted some VERY important information, like what sort of machine you're working on and whether you are having any other problems that would lead you to suspect this part. __________________ 1983 Suzuki GS850G, Cosmic Blue 2002 Suzuki Vstrom DL1000, Midnight Blue 2005 Kawasaki KLR650 - Turd II, The ReTurdening "Do not crinkle your food wrappers loudly. Be considerate to others, or I will bite your torso and give you a disease."

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01-04-2013, 03:51 PM	#4
indr ^OP Studly Adventurer Joined: Feb 2010 Location: BC Oddometer: 840	Will do.

01-05-2013, 11:38 AM	#7
indr ^OP Studly Adventurer Joined: Feb 2010 Location: BC Oddometer: 840	The bike is a 2010 Ex250. I'm assuming this could be damage because I have laid the bike down towards the shifter side more than once. Damage that could have transferred to what I see now. Also, I have tried to split the crankcase without taking out the clutch basket (stupid me) that might have put undue stress on the parts mentioned. You and concours are right in that there IS a plate/disc that keeps these apart and in normal operation, there is 0.00001% chance of these two coming undone from their places and hooking up like in 3rd picture. I am just worried about the loosness. All in all, I see no damage to the riveted area that would lead me to believe that they could have gotten that way because my mistake while trying to split the case.

01-05-2013, 02:59 PM	#9
Beezer Beastly Adventurer Joined: Oct 2004 Location: Anchorage, formerly Spenard (hub of the universe) Oddometer: 4,437	pretty sure the 2 arms are on opposite sides of the shifter drum... they can never touch when assembled. they also prolly ride in a track to keep them in alignment & have springs so they follow the shifter cam on the drum

01-05-2013, 07:10 PM	#12
indr ^OP Studly Adventurer Joined: Feb 2010 Location: BC Oddometer: 840	It shifted perfectly about a year ago before I started dismantling it slowly. The reason for spliting the case is totally different. I didn't look through the manual before trying to do pry it open. I'll stick with the way it is and replace the arm spring. Should be okay.