how to fix a stripped gearshift spindle?

[cybrman]

Just picked a pile of 85 atc110, that I probably should've left in the trash.
One of the many issues I have is that the shift spindle is stripped smooth as a baby's you know what.
One of the thoughts I had was to notch out a bit more of the shifter to allow it to compress further when tightening the bolt.
Of course my guess is this wouldn't last long if at all and so I'm wondering if anyone has any ideas for repair or if replacing is my only option. I do not want to weld it on there but that is an option as well but only a last resort.
Looking for creative ideas...
Thanks
Rick

[Tecate250]

Well you can take a washer and weld it to the shaft. Ive seen this done a few times. And it allows you to eastaly remove it later.

[jb2wheels]

Screw that - just replace it. They're like $30 on eBay. The shaft is the same from any ATC90/110.

I have an 84 ATC110 engine with a 78 ATC90 shifter shaft in it.

You're going to pull it out the RH side of the engine.

Grind/file the shaft smooth so it doesn't tear up anything on the way out.

Pop the RH engine cover off. Be careful and you might get to re-use the gasket. Of course, if it's a POS you might need a gasket set anyway.

Can't remember if I had to pull the clutch or not. It will be obvious when you get the cover off.

Good chance to clean the oil slinger/filter while you're in there. I bet it's NASTY.

[shortline10]

If you want take a hack saw and make new groves in the shaft and the same with the shifter . if you do a good job it will hold up for a while . The best way is to just change it out but taking the clutch cover off can be a bit frustrating if you haven't done one before .

[fabiodriven]

I don't like welding them either. I would just replace it but if you weld it right, it won't be hard to grind off once you are ready to replace it.

[Northman]

I have a 185 that had that problem all the time , bought new ones off ebay etc, but what i did was drill hole right through the lever and shaft and put in a cotter pin, never had problem again 4 years now

[freaksfix]

Ive had this problem on several trikes and quads. The best way is to change it out. But ive also "fixxed" them. On one I I drilled a small hole from the side so the hole was half in the shifter and half in the shaft (coming in from the side or dowwn into it if the bike where up on its side), I then tapped it and put a set screw in it, kinda like a key way in a wheel and axle, worked good..

[Dirtcrasher]

I'm never a fan of "patches" but, my 350X had a welded shaft that the previous owner did.

I waited 3 years to repair it with NOS parts. It held up fine and nothing was damaged in the welding process so I can't say that isn't a feasible thought.

If you do, just place a cold wet dripping wet rag just behind the shaft while welding it.

I have a motor and fenders and seat for that year trike that I'll sell cheap -20$ shipped Priority Mail for that shaft, most of the motor I just ask that someone makes it worth my time and the trip to the PO.......

Unfortunately the Post Office is driving me away from them as a shipping source; a 2lb package just cost me 9$ the other day, it's getting ridiculous!

The fenders and seat are in pretty good shape so I'm trying to get something reasonable for them.....But the motor isn't worth much to me aside from the pull start and sub tranny that I'm sure I can sell (in time).

Let me know if you need anything at my email below

[cybrman]

Thanks for all the responses.....some really good ideas!
This thing needs so much work that I will no doubt replace the shaft.
Got her sputtering tonight so I was happy with that. Amazing really that with a little electrical work she still has it in her....nothing like a Honda