Shift Shaft splines repair....

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10/2/2017 1:07 PM

I have a '78 RM400 shift shaft that the splines are messed up. It's not real bad, but enough to where the shift lever does not fit correctly. Anyone know how to repair the splines? Machine shop? DYI ideas? Thanks.


10/3/2017 9:56 AM

Have you tried searching eBay for new or used shaft? Once the splines are toast, usually need new shaft to fix problem correctly.....I"m always shocked at what I can locate new Oem for older Suzukis ...


10/3/2017 7:47 PM

Drummal tool and bits will most likely fix this, but remove it from the case to work on it in a vise.

Paw Paw


10/3/2017 9:03 PM


Tomac and/or Anderson for 2020.....

10/4/2017 12:35 AM

shouldn't even have to split the case. you can replace a shaft without splitting. just removing all the stuff on the clutch basket side


IG @jaredkeller96

10/4/2017 11:56 AM

Take a hack saw and cut the slot in the shifter wider. Then you can tighten the shifter to the worn splines tighter.