Question about 2005 Suzuki TF 125 Mud Bug
Wish I could see the bike but the following may help. Remove the shift pedal and look at the mounting hole. It should have groves in it which align with groves on the outside on the shifting shaft. If the groves on the shaft and / or the pedal are messed up, ( stripped ), then you need to decide what repair will work. Try re-mounting the pedal on the shaft and see if tightening the mount bolt extra tight will work. If not, you could pin the shift lever to the shaft. I don't know what bike this is but you probably have more serious problems than just a stripped shift lever or stripped shaft.......
...... A shift drum pin may have been sheared. The shift lever return spring and / or shift lever drum spring may have been broken or knocked out of place. The shift lever positioning C ring may have broken allowing the shift shaft to be out of place and not catching the shift pins. These are relatively minor problems to fix but the likelyhood is that you now have a bent shift fork......
...... A bent shift fork requires the engine be removed and torn down to about 75 pieces then reassembled with new shift fork(s). I have done this repair many times as a bike shop mechanic. Some special tools are needed and a good bit of knowhow. This is not a repair for the beginner. How about you take the bike to a dealer and ask them to just glance at the shifter and see what they think. It won't cost you to just ask for their ideas on the problem. Please post how you come out on this. I am curious what you find.
Posted on Mar 11, 2009
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