Dumped her and now I have to fix her

[S3_Captain]

After 8 years with my 02 955 I finally laid her down. DAMN! Cold tires, tight turn, hit the center line paint and the back tire slipped out from under me. Most of the fix is easy stuff (clutch lever, bar end, slider, foot pegs, left side engine case, etc). But the one thing thing that is making me nervous is the shifter. The gear change shaft has two threaded parts at it's end.

th_GearChangeShaft.jpg


The one at the very tip has the shift lever attached to it and the lever snapped it off during the fall. The S3 manual makes it look like I will need to PULL THE ENGINE FROM THE FRAME and crack it open to replace the gear change shaft!!! F***CK!!! Can anyone suggest an alternative? How strong is JB weld? I've never used it, do you think it could withstand the pressures of a shift lever?

Thanks for any suggestions.

[Metatron]

IMHO, you shouldn't need to pull the motor. everything short of changing piston rings can be done mounted.

[James33]

Iv just fixed mine. I tried to remove it through the sump but in the end i pulled the engine out and split the cases. I can't see any other way of doing it important afraid. The oil pump needs to come out and the selecter forks. Then undo the rachet mechanism on the selecter drum to allow the broken shaft to rotate clear. Just put my engine back together so get it back in at the weekend and fingers crossed.

[S3_Captain]

Ugh, that's not the news I was hoping for. Glad you got yours going again, James. I think I'm going have to hire someone for mine. How many hours do you'll have spent on it in total?

Thanks,
Matt

[dr_gallup]

You have to replace the shaft, JB weld is strong but it's not going to work here. Theoretically the shaft could be welded but I'm 99.9% sure you would damage the oil seal if not the case.

[James33]

Not really been counting the hours but i recon its about 6 so far and my engines still out of the bike so can probably and another 3 to that. I replaced thee oil seal on the shaft and also its worth fitting a new seal on the output shaft behind the front socket and a new oil pump strainer. Check yours hasn't split already, if it has then for peice of mind id replace the oil pump too. Double check though my manual says the 02- is slightly different so if yours has the later engine it then you might not have to drop it.