need help replacing a shift shaft on my kawasaki buyou 220?

Question

i need basic directions on were to start to replace the shift shaft (i hope that s the right description) on my kaw buyou 220. the shaft broke off at the foot shifter that goes into the transmission. i need pictures or basic directions were to go before i make a mess. thanks

Answer 1

Always give year, make, engine size and model # when asking questions. Bayou 220's were made for over 10 years with a lot of changes along the way.
-Drain oil
-Remove R crankcase cover
-Remove clutch
-Fiddle around with the shift mechanism, you'll see how simple it is.
-Notice how the heavy duty spring is spread open around the tab on the shift shaft (don't lose the washer).
-Since you broke the shift shaft, the end could be bent. You might have to tap it out with a long drift, ratchet extension or screw driver. Use what fits.
-Change the shift shaft seal. It's only a few bucks. The seal could've been damaged when the shaft broke. If you have to tap the shaft out, that could damage the seal.
-To change the seal - pry the old one out with a screw driver (careful not to damage the case that the outside surface of the seal touches). Tap the new one in gently (so it goes in straight).
-Here's a picture
http://www.bikebandit.com/partsbandit/OEM-Parts.asp
Look at Gear Change Mechanism. Bayou 300 is the same.
Look at Clutch to see how to remove the clutch.

Answer 2

u take off the clutch cover on the right hand side of the engine inside there should be thee oppisite end of your shaft. its a bit fidley to do but if u get stuck email me on [e-mail] paul

Answer 3

Maybe, but I'm not 100%

Answer 4

that's a good question and I hope you will get some valuable answers

Answer 5

thank you for the replies, very much appreciated.