shifter shaft broke

Dblhdr, one of our members, has just informed me he was on his way to work and he broke his shifter shaft. It is a 1979 police model with the heal toe shifter. He says it's the shaft that comes directly out of the engine.
What all is involved with replacing this thing?
Possible to replace without splitting the cases? (pray pray pray).
I've heard of the shifter breaking, but never the shaft coming from the engine.

IF and I do say IF it's like my old Z1, the shaft does NOT go into the cases. As I just found out this week, see my posting on broken shifter return spring.

It might be a total different animal too.

A real simple item to get to also. Took me about ten minutes maybe. And that included fighting 37 years of grim and stuck screws.
Pat

Thanks Patmann. That thread gives us a little encouragement.
We have a memorial day weekend ride planned and hes at near panic already. As a matter of fact, he's now paniced enough to buy a Concourse 1400. :laugh:
All fine and dandy, but I think another shaft might be cheaper.

Wondering if it's broken @ a place that's weldable??
Weld it for now, and and look for a used new one??

pretty sure that you just pull the countershaft sprocket and then pull the cover behind the c/s sprocket and it is right there with the pauls(hooks) on it.a lil short feller.no step for a stepper.

leon

check the link.
www.babbittsonline.com/pages/parts/viewbybrand/default.aspx

you guys got this no sweat.you may wait just a lil bit and let him get the conny so you can borrow it for fixing his cop bike. :laugh:

leon

p.s. you will have to fill in the bike info then go to gear change mechanism and you can see the parts.after that you can go to engine covers and you can see the cover that you have to remove.hth.

I have a .pdf excerpt from the Service Manual showing the external shift mechanism, but don't know how to post it. It's about 8 meg.
Tim

very simple job shouldn't take much time at all he will be up and riding very soon.

Here's the broken shaft
powers edge has a new one for 70 bucks plus shipping.
I haven't looked for a used one yet.

I decided to take a look under the chain cover before I ordered the parts I would neeed. I think that I will order a new clutch cable when I get my parts. This one looks like it could be original. I scraped thirty years of gunk out from under the sprocket cover.. I've never pulled the sprocket before. Is there anything I need to know before I start taking it apart? do I need to loosen the chain before I take off the sprocket? :blink: Should I get some help over here?

Here's a picture after scraping most of the gunk out.
:X

Keep the chain on to help loosen the nut on the sprocket.you might need someone to stand on the rear brake for added resistance.

On some Kawasaki's, a metal washer had edges folded over to lock the engine(or countershaft sprocket) to the output shaft.A cold chisel and hammer will straighten out the bent tabs.

I'm probably wrong, but I think the nut is at least 22mm. I used a 1/2" long breaker bar to get my bike's sprocket nut off when I changed chain and sprockets.

While you're in there,carefully pull out the clutch push rod,clean off the accumulated chain lube,clean and re-lube the push rod mechanism.

The three yellow wires seen in the picture are the ones from the alternator stator, check the "Bullet" connectors on them for over heating and corrosion.