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.
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Shift Shaft splines repair....
Posts: 301
Joined: 4/8/2014
Location: Ormond Beach, FL USA
Posts: 3303
Joined: 3/21/2014
Location: Saratoga Springs, NY USA
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 ...
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Posts: 597
Joined: 12/24/2011
Location: Benton, LA USA
Drummal tool and bits will most likely fix this, but remove it from the case to work on it in a vise.
Paw Paw
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Posts: 7122
Joined: 10/31/2013
Location: PA, USA
Posts: 463
Joined: 11/8/2015
Location: Huntersville, NC USA
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
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IG @jaredkeller96
Posts: 265
Joined: 2/2/2017
Location: Atlanta, GA USA
Take a hack saw and cut the slot in the shifter wider. Then you can tighten the shifter to the worn splines tighter.
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