DR200 problem

[earl34]

Hello from Scotland.

I have a 1989 DR200 with a snapped gear shift shaft.
It's snapped at the point were the lever retaining bolt would sit, so only half the splines are present.
Has anyone replaced a shaft?
Can it be replaced without splitting the cases? (from the clutch side perhaps).
Any advice appreciated.

[Kickaha]

Can it be replaced without splitting the cases? (from the clutch side perhaps).
I just checked the one I have in the garage and yes it can

[Katman]

Yes, it can be replaced without splitting the cases.

You'll have to remove the clutch basket though.

[Kickaha]

You'll have to remove the clutch basket though.
Would you like to wager a chocolate fish on that?

[Akzle]

Hello from Scotland.

I have a 1989 DR200 with a snapped gear shift shaft.
It's snapped at the point were the lever retaining bolt would sit, so only half the splines are present.
Has anyone replaced a shaft?
Can it be replaced without splitting the cases? (from the clutch side perhaps).
Any advice appreciated.


build it up with weld and then needle file a new spline on
:D:D

(bt srsly, it's fucked. if it's broken at this end, it's likely it'll go at the other. and that could be hilarious/catastrophic, depends who it happens to)

[Fast Eddie]

i love choc fish, ill wager you don't need to take clutch basket off

[Katman]

Would you like to wager a chocolate fish on that?

I'm suddenly not so sure.

[tri boy]

I'm suddenly not so sure.

Post of the year.:2thumbsup

[Katman]

Post of the year.:2thumbsup

Haven't you got a Chinese scooter to assemble?

[ducatilover]

Would you like to wager a chocolate fish on that?
Sure, why not :crazy:

[gammaguy]

Sure, why not :crazy:

my manual here says you have to remove the rear wheel,replace the cush drive and then strip the swingarm,suspension and the rear brake lever to remove that shaft.

no mention of a clutch basket tho.....:crazy:

[ducatilover]

my manual here says you have to remove the rear wheel,replace the cush drive and then strip the swingarm,suspension and the rear brake lever to remove that shaft.

no mention of a clutch basket tho.....:crazy:
It's at the arse of the motor just about 8 o'clock to the clutch, so I'll find a choccy fish and send it to Kickaha (after I check my DR when I'm home)

[Fast Eddie]

so I'll find a choccy fish and send it to Kickaha and Eddie

i was in on the bet too

[ducatilover]

i was in on the bet too
Fuckin' freeloader :bleh:

[actungbaby]

build it up with weld and then needle file a new spline on
:D:D

(bt srsly, it's fucked. if it's broken at this end, it's likely it'll go at the other. and that could be hilarious/catastrophic, depends who it happens to)

trouble with that fix is usually cooks the rubber oil ring and htne you have leaking oil making a mess

[Akzle]

trouble with that fix is usually cooks the rubber oil ring and htne you have leaking oil making a mess

you need to learn to weld better. :D

[tri boy]

Haven't you got a Chinese scooter to assemble?

Left that shit years ago sonny,
try and keep up.

[ding322]

trouble with that fix is usually cooks the rubber oil ring and htne you have leaking oil making a mess

You gain 2 things though - a working shifter and a easy to view sight glass ;)

If it was me I would just replace it - if you gotta split it then so be it

[earl34]

Thanks for all the advice.
I replaced both the shaft and the oil seal.

Some "choccy fish" need to change hands, the clutch basket stayed put.
Thanks again.

One more thing, is it safe to use the later model workshop manual?
I can't find one for a '89 anywhere.