KLX125 Gear shifter slipping - how to fix?

[-JT-]

On my sons KLX125 the gear shifter is slipping. Because of this I replaced the actual shifter with a new part (correct part) but it still slips no matter how tight the screw is. It appears the actual shaft is worn and the 'grip' isn't as pronounced.

The only ways I can think of fix this are very 'no-8-wire' and not ideal ie: weld or pins. Any good suggestions from anyone that I could do myself?

[F5 Dave]

Sadly they get loose & people don't tighten them. Chances are foofoo bikes are made in China parts so not hardened very well. Welding is just the nastiest way.
Does the clamp bottom out (close up tight)? if so you can put it in the vice & squeeze it together & hacksaw the join line. This will help give more clearance to the clamp & help it grip tighter.

You would be better if this fails to find another (same size) gear spline from another bike & remove the old one & re attach the replacement shaft to the original shaft at a position that isn't in a bearing surface or seal. Obviously the weld will have to be top-notch. If you grind out the original & weld the new shaft into the plate (cut flush to plate then drill out remains) that will give you a good as new arrangement, but the shaft will need to be altered to same length & be the same length on the case side as it locates there as well.

Might have to draw a pic if this doesn't make sense.

[pete376403]

Get a couple of rollers from a needle roller bearing (eg two stroke small end bearing) and drill holes slightly smaller half in the shaft, half in the lever (ie you are drilling parallel to the splines with the lever on the shaft and in the correct position), Tap the needles in and tighten the clamp. THis is a last ditch metho, as you won't be able to adjust the position of the lever. F5 Daves idea of cutting a bigger gap into the clamp should be tried first. OR just bite the buleet and buy a new gear selector shaft and lever.