DR200 problem

**earl34** · 18th September 2012, 19:47

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** · 18th September 2012, 19:55

Originally Posted by earl34

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** · 18th September 2012, 19:59

Yes, it can be replaced without splitting the cases.

You'll have to remove the clutch basket though.

**Kickaha** · 18th September 2012, 20:02

Originally Posted by Katman

You'll have to remove the clutch basket though.

Would you like to wager a chocolate fish on that?

**Akzle** · 18th September 2012, 20:05

Originally Posted by 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.

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

(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** · 18th September 2012, 20:06

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

**Katman** · 18th September 2012, 20:14

Originally Posted by Kickaha

Would you like to wager a chocolate fish on that?

I'm suddenly not so sure.

**tri boy** · 18th September 2012, 20:25

Originally Posted by Katman

I'm suddenly not so sure.

Post of the year.

**Katman** · 18th September 2012, 21:50

Originally Posted by tri boy

Post of the year.

Haven't you got a Chinese scooter to assemble?

**ducatilover** · 18th September 2012, 22:48

Originally Posted by Kickaha

Would you like to wager a chocolate fish on that?

Sure, why not

**gammaguy** · 18th September 2012, 23:03

Originally Posted by ducatilover

Sure, why not

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.....

**ducatilover** · 18th September 2012, 23:07

Originally Posted by gammaguy

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.....

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** · 19th September 2012, 10:24

Originally Posted by ducatilover

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

i was in on the bet too

**ducatilover** · 19th September 2012, 13:57

Originally Posted by Fast Eddie

i was in on the bet too

Fuckin' freeloader

**actungbaby** · 19th September 2012, 14:36

Originally Posted by Akzle

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

(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