Hey Larry,
The gear shift splines are the same for all the models below. If you can find a a good shaft off another model that has good splines, you can cut off the appropriate length off one of those (about 2" I think, been awhile since I looked at mine) and weld it to your old shaft, after cutting the same length, plus about an 1/8"of your old one. The ends should be ground like below before welding...not like a cone....like a chisel, leaving just a very small gap between them. Welding them in a clean 'V' block will keep them square and even with each other. It needs to be perfectly straight. A good welder will leave just a very small gap.... make his first pass.....flip it over...shine up the weld...second pass....rinse and repeat as needed and grind smooth.
Clutch cover off only to remove and reinstall the gearshift shaft....no need for any case splitting. Just be sure of the add on length...you don't want the shaft to come up short at the engine sprocket cover where the shifting lever installs to the shaft. Better a tad long then short.
Also, you may be able to come across a T500 shifting shaft that had splines on both ends. You wouldn't care if the splines on the leftside were bad....the splines on the rightside would of course be 'virgin' splines.
But.....if you try and mate a a gear shift lever that has just fair to bad splines onto the new or good splines you now would have on the shaft, you could mess up both the shaft splines and the lever splines.
I have had to do this once in the 25 years I have owned my '75 T500M and am now prepared to do it again soon with a spare gear shift lever that is like new. Below are pics of a good spline end next to an old T500 shaft. I cut the end off a GT250 shaft from ebay. The seller had happened to recently electroplate it.
Good Luck
Copied and pasted text from Partszilla website.....
Related Fitment
This Suzuki 25600-18001 LEVER ASSY, GEAR SHIFTING | 1,2; TO 25600-18002 Not Available fits the following models and components:
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