KLX110 shift shaft replacement help

[smokinjoe]

Ok so out on a railbed trail Joey had a get off and the ONLY thing that happened to his (06?) DRZ/KLX110 was the shift shaft was sheared off at the shifter(!)

A fun adventure ensued trying to extract the bike from the wilderness (riding Joey and rocko the dog on my bike to find a house to knock on the door to borrow their side by side etc)

My question is does anyone have knowledge of the replacement procedure?

I have the part and gasket but do I need a special puller/extractor to remove the old one or can I do it with normal tools?

There is no utube vid on it only on a crf110 and he uses a special tool.

Any help or insight would be hugely appreciated as we usually go riding weekly. Thanks guys.

Joey is my 10yr old son btw.

[Kurlon]

Should be a ton of vids online for the KLX, look for ones showing 'adding 4th gear', same process, you'll just stop at pulling and reinstalling the shift shaft, leave the transmission and shift drum alone.

[smokinjoe]

Thanks man I actually did that yesterday with a vid for clutch replacement.

Next issue>

The klx shaft got bigger from 05 on. I installed the newer bigger one with no problem except my shift levers dont fit now.

I am looking for a stock size (5 inch) aftermarket shift lever.

The stocker is $70 but aftermarket is $24ish.

The aftermarket caters to adults using this as a pit bike. My son is 10 so cant use those longer shifters.

[Kurlon]

Hit up Vince at TBoltUSA, they've got reasonable priced shift levers in 1in under, stock and 1in over length.

[smokinjoe]

OK so did the shift shaft swap to the post 05 stouter shaft and got a new shifter from amazon (faster delivery). I ordered one from TB but it would not have come in time to go riding yesterday.

We did many trail miles in upstate NY and the bike worked perfectly.