*NOT* a trail side: hack broken shift lever bolt replacement

Here’s a ride damage situation there’s no way to make a trail side repair for so this KTM had to be ridden out of a back canyon on the Toquerville Twist Utah ride back to the truck in second gear.

Once back at the Taco Shop©️🌮🛠🛴🔩 this needed to get to the OR for a few procedures to get sorted out.

this was on a 500excf but all 125-570 Austrian bikes are all the same for this set up.

*Important note: we heated this shaft to 300-350 deg f checked with a digital infrared tester, the typical temp to release thread lock compound. Don’t overheat a tempered / hardened shaft or tool to avoid damaging its temper / hardening properties.

*correction, note that in the rest position the shift drum and shift jaw sit with the two pins of the drum flat against the jaw and not just one as stated in the video.

Let us know if you have any questions about this or anything else on your KTM, Husaberg or Husqvarna dirt bike, and don’t forget to like and subscribe🤘🏽

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[paul.vanhout]

Great lesson on something I hope I never have to do!

[Toad_Moto]

There is always that one guy on the dirt bike page who has to be a hater.
Nice fix, dude.

[MrSuper]

Thanks! I managed to get it out with a heat gun and pick, I'm glad I didn't have to drill it, since it snapped flush. My friends bike had the same issue but it snapped inside the shifter shaft.

[astonjorgensen]

how did u actually take the shift shaft out

[lochspey]

Good info, thanks! I wonder if a weak "break-away" section such as shift and brake levers have could save a ride and still be usable enough to get out of the back county instead of breaking in a bad section?

[johnfavre]

Bring it to a good tig welder that has worked FAA repair to get that broken bolt out!

[ronsroom]

Hey Mike, Thanks for the video on this. I’ve had the same thing happen on a FE350. I was lucky enough to be able to back the broken bolt out using a pick. I now have a titanium shift lever bolt on my 500 xcfw (purchased from you). How do you think these Ti bolt would handle this type of impact? And would you be able to tap a Ti bolt like this?

[Taite]

I’m having this issue right now! Bike tipped and slid down hill. Shifter hit a boulder in the ground pushing the shifter down into first. My issue is the shaft now needs a 3/4 of a turn before it will shift from neutral - 1st or vice versa.
Would u know why ?

[spyplane]

bike will still shift without the linkage just need to know foward is up and back is down. I had to do this to my vitacci to get it to ride to work daily mine broke so im up a creek with no paddle. Good luck finding parts for a gtx 250 .

[LaurenceHoneytoast]

I never actually broke the bolt off of there myself. I did snap that weld on the shift shaft tho. Lol

[Papparratzi]

Looking for a shorter shift lever for a 17 FE 350.
Is one available at Taco?

[crazybobmo]

Uh, After you have made a shift, there are Two splines sitting against the shift ratchet. Not one centered....Resting in the middle position.
The ratchet retracts when the shift shaft is Returned to center by the 'Return spring', in preparation to go to the next gear.
And, Yes, I DO use medium Loctite on the shifter retention bolt....
ALSO, Do Not Apply heat to the 'Highly Tempered' Easy-out tool.... You have ruined yours.... >;)