Xr650l Gear Selector Shaft Replacement

Can any body please tell me if there is an easy way to replace my broken gear selector shaft on my 2005 XR650L? Can it be done without pulling the engine completely down?

Can any body please tell me if there is an easy way to replace my broken gear selector shaft on my 2005 XR650L? Can it be done without pulling the engine completely down?

no, sorry. time to split the case.

Yup, sorry to hear this, but you are into a full teardown.

Faced with a similar situation that I'm still in, I would suggest you open your wallet, do some research, and turn your XRL into a 50HP beast.

:crazy: The cases :D have to be :applause: split :bonk: .
Yup, sorry to hear this, but you are into a full teardown.

Faced with a similar situation that I'm still in, I would suggest you open your wallet, do some research, and turn your XRL into a 50HP beast.

ya in a sick kinda way i almost hope something happens to mine so i can justify to wife that i need to build a 50 plus hp xrl!

I just split my case last night. It's not that bad. I strongly suggest you get the proper tools though. You'll need a 27mm socket, a 30 or 30mm socket, a case seperator, a clutch basket holder, and a flywheel puller. I got mine on ebay for $100.

Thanks for all the bad news, I had my local Honda service agent quote me $1000 to do the job, $800 labor and $200 parts ($80 per hour!), Do your US bike mechanics charge that much? I promptly picked the bike back up to do the job myself. I have since stripped the engine down, and replaced the broken shift shaft ($77 Aust.). I have also taken your advise to add a few more HP while Ive got it in pieces. I have purchased a wiseco piston (10.25-1) kit, and a hotcams stage 1 cam. I am also planning on sending the head out to be ported and polished? Is there anything else i should be considering while its in bits? Oh, the other thing i know I want to add is a stainless header pipe (I already have a white bros. E2 pipe), Which make header should I go with?

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!


Register a new account

Sign in

Already have an account? Sign in here.


Sign In Now