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Author Message   Whodom Posted on Monday, July 04, 2005 - 01:43 pm:        I'm presently putting my S3 back together after finding a stray snap ring in the transmission oil last weekend (see the Quickboard for the thread). I've got the snap ring reinstalled and my primary back together, but I think I've found what lead to this problem in the first place. I installed an updated 2001/2002 shifter kit on the bike as soon as I got it. I had a lot of trouble getting the linkage part that goes on the shifter shaft installed (which lead to use of a dead-blow hammer, which lead to a snap ring inside the transmission popping off- not smart). This morning, I think I found the root cause of the problem. The shifter splines don't seem to be machined correctly on the shaft. I added some black lines to show the problem. The splines on the back half of the shifter shaft are approximately 1/2 spline "off" from the splines on the front half of the shaft. The "mating" splines in the shifter linkage piece are machined straight, all the way through the piece. The original shifter section that mounts here has no splines in the "rear half", so this wasn't a problem. My question is this: Was my shifter shaft machined incorrectly, or was my 2001/2002 shifter linkage part machined incorrectly? Any comments would be appreciated.   Natexlh1000 Posted on Monday, July 04, 2005 - 09:47 pm:        You think it's possible that the shaft was tweaked?   Whodom Posted on Monday, July 04, 2005 - 10:11 pm:        I don't see how it could have happened without wrecking the linkage inside the transmission (which works fine), but I suppose it is possible. It seems like whatever machining process they use to machine the splines would make them line up, so maybe something like that did happen. I ended up taking a Dremel tool with a small grinding stone and grinding away part of the splines in the linkage piece. There's actually still enough depth to the splines even where I ground for it to hold, but it will slide onto the shifter shaft with minimal resistance and the outer splines still fit perfectly. I think the problem is taken care of. Of course, I'm still waiting on a shaft seal which my local dealer didn't have in stock. Hopefully that'll show up tomorrow.

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