I took it out and put it back in in winter. Now wanted to remove it again because I decided that little 106" lb torque on the detent arm and shift cam really should have a backup of thread locking agent as specced in the SM.

I got the parts I wanted out but darned if that shift shaft would come out. It just about comes all the way out and then it hits against something on the other side of that clutch case wall. Don't know what it could be. The shift shaft tapers down before the serrations so I believe it has something to do with that----allowing another part to drop down in the tunnel and catch on the edge of the serrations.

The shaft was perfectly straight when I put it in. I checked. No excessive wear, just some marks where it contacts something in there but no actual reduction of the diameter. It did take some cajoling to get it out and in the first time but now???? I didn't want to force it.

There is a set of roller bearings on either end of the shaft, isn't there? Maybe the inner set is what's dropping down on the edge of the serrated part. I did not lube the thing before reinstalling it. Figured there must be oil in the tunnel since the shaft was dripping when I took it out. Now it is dry like when I put it in.

Maybe some oil would help the shaft slide out?

Thoughts?

http://www.cheapcycleparts.com/oemparts/a/kaw/500b62eef8700223e4797276/gear-change-mechanism

480 circlip off?
Circlip groove could hang in the case hole. So the trick is to spin the shifter shaft from [the clip groove] digging in the case.

Yep, you ain't going nowhere without removing that outer circlip. That's all you really need to remove to pull the shaft out. I did try turning it. Maybe just a little oil. There was oil on that thing when I took it out.

Also, possible I turned up a bur when I put a vice grip on the shaft to shift. I doubt that. I wrapped it in a rag and it wasn't all that tight. I'll have to have a look-see in the AM.

Thanks, Hub. I'll let you know what I find.

Did you first slide the shaft INTO the crankcase into the needle bearing?(on the left side)The end of the shaft where the splines I mean.After removing the clip.THEN,go to the other side,and gently pull,turn the shaft.Being careful not to cock it in any direction.Good luck with this.It just needs some finessing,that's all(IMO)I remember with my 07,I THINK I had it on it's sidestand.When the shaft cleared the right hand side,I happened to look under the bike,oil was freeflowing EVERYWHERE.A mess.
I don't think anything is 'dropping down' into a groove or something...all you have is bearings...that aren't gonna go anywhere.You just need to go slowly and gently.Push it back in a bit,and go for it again.It'll slide free.Sounds like you may be angling the shaft(since it's at the very end of it without any real support).So yeah...pretty sure that's what's going on.

* Last updated by: Grn14 on 6/27/2017 @ 11:47 PM *

I think you're right Grn. Far as I can tell, the bearings and grease seal should stay on the LH side so all there is to stop the shaft on the RH end of the tunnel is the groove for the circlip. This bike has almost 50k miles. That circlip might have raised a slight edge against the wall of that groove. 50K is a lot of shifts. If I ever actually need to remove the shaft, I guess a needle file and emery paper.

Also, the shaft is bone dry right now. Thanks for sharing your oil spill tale. That tells me that oil in the tunnel is how it should be (I guess that's what that grease seal is for). I saw the oil too but it came into the clutch case because the bike was on a sidestand. I thought maybe the shaft was drenched from an oil overservice but it appears that's how it is supposed to be. I'll probably pull it far as I can and squirt some oil in there. That migh tbe enough to get to come out pretty smoothly. Hate to put any force on things if they are supposed to slide right out. LOL learned that the hard way a couple times!

OUCH

TWSS.

So, I tried pulling the shaft again and I see it comes through about a quarter inch AFTER the circlip groove enters the clutch compartment. It's not that circlip groove.

Looking at it from the other side, I see there are scuff marks about a quarter inch to the left of the groove. Apparently it scuffed pulling it this winter when it was about 2° F in the storage unit. I'll bet the cold shrunk the part and it passed through the hole with minor persuasion. Not going to happen in summer.

Somehow, I got me a fat shaft.

or----OR--is it a bent shaft?

I'm converting to GP shift so maybe it will bend back the other way.

I swear I'm not trying to be dirty here.

I'll bet the cold shrunk the part and it passed through the hole with minor persuasion.

Just so long as you aren't driving tonight Rook your good.

Maybe try spraying with LN2 to cool the bitch off until you can slide your shaft out of her

Can you pull that metal washer off there?Behind that are the needle bearings.It MIGHT be hanging up on those.And maybe buff off those burrs there.Nothing major.That shaft WILL come out.You're just not getting the right pull-out angle or something.Can you hear anything just as it hangs?Pretend you were using brail.

So let me get this right here...the shaft WILL pull outward(from the other side there)and the tip where the splines are WILL be flush with that washer,right?Then it hangs up?

"I took it out and put it back in in winter"...okay,so you KNOW it WILL come out.Okay...so here's what ya try next...get to the party store,buy some glass freezer(champagne spray in a can).Spray that exposed end there really nicely.Get it really cold.THEN try again.(after deburring).Only the shaft,not the surrounding bearing in there.

* Last updated by: Grn14 on 7/2/2017 @ 9:50 AM *

I never had to pull the washer off when I removed the shaft. It just stuck there but I'm sure I could remove the washer.

Yes, I hear/feel it hitting solid on the other side of the clutch case wall.

So let me get this right here...the shaft WILL pull outward(from the other side there)and the tip where the splines are WILL be flush with that washer,right?Then it hangs up?

You got it up to the part about the washer. It pulls all the way through the washer and the bearings. I can see the groove for the circlip in the clutch case---thats how far it pulls through! See the circular scuffs? I cant see that but I see eveything else sticking out of the clutch case wall. I can't get it out far enough for the bur to even enter the hole in the clutch case wall. I think it's that the shaft wedges in the hole. The shaft is too fat or it's bent enough to bind in the hole. Funny though--it feels like it is hitting something, not slowly wedging into the hole like I would expect. Tell ya the truth, I didn't want to beat it back and forth in there so I have not tried to find out how hard it hits.

I'd have to order the champagne spray. IDK how that would work. The cold is going to want to disperse through the whole shaft. I'll need 12 cans of spray. I think emery paper and take it down a few thousandths. I think the scuff is only on the bottom which is telling me it's bent just enough to catch.

Well...I thought maybe it was hanging at the spline area.I mean,you could chill that end there and see if it slips through all the way?It might.It came out before.It HAS to do that again.I wouldn't hit it with anything.The scuffing is only on the shaft,right?

http://pdn1.vnexttech.com/kaw/mc/i1415/gear_change_mechanism/assembly_files/11/1_1.png

The scuffing is only on the shaft,right?

It's very minor. I'm sure if the shaft scuffed, the inside of the hole I pulled it through must have also scuffed.

I might hit it with some emery cloth and see if it comes out. Otherwise, I guess that's up to whoever pulls it in the future which will probably be me. It works fine. Maybe I will change it next year when I change clutch fibers. It's a $50 part. Probably order one and have it on hand since parts seem to be getting discontinued on this darn thing even though the last model was only 6 and a half years ago....six and a half years...shees my bike is going on ten! I bet I'll have it when I'm 80 and be making my own parts for it.

I dressed down those small gouges with a needle file, wiped 'er off and pulled 'er right out! You see there are a few teeth that got squashed by the vise grips, too and I'll try to clean those up with my triangle needle file. I was careful to put a folded rag over it before I grabbed it with the vise-grips and I did not go super tight on the grips either--but I guess that is a no-no rag or no rag, tight or not tight.

Probably put his brute back into service for a few seasons but I will be ordering a new one. That clutch basket and hub will need to be replaced down the road too. Do 'em all at once when I'm like 60...LOL!

Moral of the story: Ride FAST, wrench s-l-o-w, very slow. Take your time, be very careful and very methodical because you're still going to f$$k up once in a great while no matter what. So here's another story of me learning the hard way. Glad I detected the problem before I torqued the clutch down or else I'd be down on the floor with the needle file trying to fix those teeth.

* Last updated by: Rook on 7/3/2017 @ 2:45 PM *

Never saw a freshly machined shift shaft before but that groove for the circlip looks as though it has worn a bit wider than it should be too.

WoHOOO!VICTORY.Pesky burrs.

I just filed the crushed teeth. Shift knuckle went back on at the exact position it was at but will not go on a notch forward. I believe it was like that to begin with. Worn to match the teeth of the shaft, I guess. Oh well, that's solved.

Hub, Grn, rudy---I've got more problems now.

http://zx14ninjaforum.com/messages.cfm?threadid=1871FB6C-CAAC-9662-936A0A92A44665EC&page=2(

* Last updated by: Rook on 7/3/2017 @ 9:20 PM *

I wouldn't have a CLUE as to how to know what gear it's in just by looking.Is there a way?I'm not sure I understand what your problem there is.I can't see any reason why it would not go into 1st and N.I mean,it kinda has to doesn't it.This is your NEW shift star?Been so long since I did this deal.Can the gears be 'in another gear' so to speak?Is the position of the star teeth where they need to be?I just pulled my shift shaft out,replaced the star just how the og was,then buttoned everything up.It worked fine.I can't remember if the gearbox was in N or 1st when I did this.I think I had put it in 1st..so the allen wouldn't turn as I loosened or tightened it.Does that sound right?

It sounds like the gearbox had been 'shifted' into another gear during that lever removal or something.Is that possible?Maybe your '2nd' is actually,1st?Hell,IDK.If anyone would know,it's probably HUB.(no offense to anyone else here).

I can't find my zx14r manual.It probably has a procedure for aligning the gears(what gear to have it in or whatever) and such prior to removing the shaft."gear change mechanism' replacement or something?Pretty sure that 'shaft' the star goes into needs to be in 1st though.OR the wheel chocked?(locked)to get that allen out.Mine was so tight,I thought the wrench was gonna break.

* Last updated by: Grn14 on 7/4/2017 @ 10:33 AM *