Hawk 250 engine parts - shift lever (not just pedal)

richinar · 12-12-2017, 02:22 PM

Sooo
The shift lever broke on my Hawk yesterday after a slow low side yesterday. Not the pedal, no, no, but the lever rod itself just inside of the splines. Twisted right off. This is a stock pedal clamp with my own bolt. Suspect I shouldn’t have used a bolt that wouldn’t strip out and allow the clamp to shred.
Yay!!!
Who carries stock engine parts and is responsive? Does the TT250 engine match?

**JerryHawk250** · 12-12-2017, 02:41 PM

The TT250 looks like a possible match but not sure. Check with TXpowersports

richinar · 12-12-2017, 04:44 PM

Ah. I didn’t see that Txpowersprt had the Hawk
I have been in touch. I bet that’s it.

In cracking into this I’ll need a book.
Which Honda engine should I look for a manual on?

**JerryHawk250** · 12-12-2017, 04:55 PM

Quote:

Originally Posted by richinar

Ah. I didn’t see that Txpowersprt had the Hawk
I have been in touch. I bet that’s it.

In cracking into this I’ll need a book.
Which Honda engine should I look for a manual on?

I have two manuals I can email you. PM me your email address and i'll send them to you.

richinar · 12-12-2017, 05:59 PM

Thanks a ton
So, could I presume that a CG125 gearshift linkage and spindle will also fit? A Honda part would ease my mind.

**JerryHawk250** · 12-13-2017, 08:39 AM

Quote:

Originally Posted by richinar

Thanks a ton
So, could I presume that a CG125 gearshift linkage and spindle will also fit? A Honda part would ease my mind.

That I could not answer unless I had one in hand to take measurements.

richinar · 12-13-2017, 03:11 PM

Local dealer had no new but did have a used part - in fact, they had 3!
$20.82 including tax
have test fit everything and its a perfect match

Honda is shorter by a pinch - not a problem at all
the big difference is the spindle material

will post detailed side by side comparison later

THANKS for the help!!!

**JerryHawk250** · 12-13-2017, 03:14 PM

Quote:

Originally Posted by richinar

Local dealer had no new but did have a used part - they had 3!
$20.82 including tax
have test fit everything and its a perfect match

Honda is shorter by a pinch - not a problem at all
the big difference is the spindle material

will post detailed side by side comparison later

THANKS for the help!!!

That's good to know. You and franque have uncovered valuable information. Another part number to add to list.

richinar · 12-13-2017, 06:05 PM

Here we have the stock Hawk shift lever spindle beside the Honda part 24610-107-760
Hawk is gold tone electroplated while Honda is light silver

The shaft end which butts against the right side cover is much rougher on the stock part with a very course machining done at the factory, probably not a big deal in this application.
the Honda part also has a small dimple in the center

While a workshop manual suggested removal of the clutch and oil pump would be necessary, it was not. Only had to remove rear brake pedal, kick-starter lever, disconnect clutch cable, also remove header pipe for easier access to clutch connection, and the right side cover. All eleven bolts for cover are 8mm flange bolts with one being longer than the others (the long one is forward most on the case).

I don’t have a metallurgical degree, but experience with steel bolts with these appearances used in other automotive applications, I know which I would think is stronger.

As far as measurements, the only differences is the stick out from the crankcase will be 5mm shorter with 4mm coming off the shaft before the spline and the outer splined portion being 1mm shorter. The welds, plate and spring seem to be comparable.

richinar · 12-13-2017, 06:55 PM

Views of right side interior shown here
Forgive the rotated images

The forward-most mounting for the cover has a small sleeve protruding from the case for alignment assistance, this is where the long cover bolt goes.

Remove the cover straight back a good distance to clear the kick-starter shaft.

Looking at the shift plate in the next image, there is a circlip (removed in detail photo) which is removed from the gearshift spindle and then a spring retaining this plate. Ease the plate out and then the shifter can be withdrawn through the right side. When re-installing, be sure to use a little assembly lube or oil and align the tabs of the large spring to go on each side of the case extrusion for such purpose.

The clutch engagement rod has a notch cut out which did not seem to show any problematic wear.

BlackBike · 12-13-2017, 11:42 PM

Good for you for jump in and getting this fixed

Sport Rider · 06-17-2018, 08:57 PM

thanks for posting this info. today my son and girlfriend went down on the grass and broke my shaft off too. replacement time.

I've not done something like this before, so if anyone has any other details on repair, I'm all ears.

reeothec · 05-02-2021, 11:54 PM

this saved me a bit of time
about to throw it in when i get the replacement. hoping i can do so without having to remove the clutch.

12-12-2017, 02:41 PM	#2
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,545	The TT250 looks like a possible match but not sure. Check with TXpowersports __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
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12-12-2017, 05:59 PM	#5
richinar Join Date: Nov 2017 Location: Little Rock Posts: 27	Thanks a ton So, could I presume that a CG125 gearshift linkage and spindle will also fit? A Honda part would ease my mind. Last edited by richinar; 12-12-2017 at 09:10 PM.
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12-13-2017, 03:11 PM	#7
richinar Join Date: Nov 2017 Location: Little Rock Posts: 27	Local dealer had no new but did have a used part - in fact, they had 3! $20.82 including tax have test fit everything and its a perfect match Honda is shorter by a pinch - not a problem at all the big difference is the spindle material will post detailed side by side comparison later THANKS for the help!!! __________________ ———— ‘16 Hawk 250 changed up a bit ‘85 Virago 1000 changed a bit more Last edited by richinar; 12-14-2017 at 12:29 AM.
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12-13-2017, 11:42 PM	#11
BlackBike Join Date: Feb 2016 Location: George West, Texas Posts: 4,097	Good for you for jump in and getting this fixed __________________ ***************************************** 2015 Bashan"Blaze" BS250GY-31 (DB-07K-250) GONE 2017 Suzuki V Strom 650 XT "We are all born ignorant, but one must work hard to remain stupid." ~Benjamin Franklin~
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05-02-2021, 11:54 PM	#13
reeothec Join Date: Apr 2021 Posts: 4	this saved me a bit of time about to throw it in when i get the replacement. hoping i can do so without having to remove the clutch. Last edited by reeothec; 05-05-2021 at 01:26 PM.
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12-12-2017, 04:44 PM	#3
richinar Join Date: Nov 2017 Location: Little Rock Posts: 27	Ah. I didn’t see that Txpowersprt had the Hawk I have been in touch. I bet that’s it. In cracking into this I’ll need a book. Which Honda engine should I look for a manual on?
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06-17-2018, 08:57 PM	#12
Sport Rider Join Date: Jan 2016 Location: Mooresville NC Posts: 2,035	thanks for posting this info. today my son and girlfriend went down on the grass and broke my shaft off too. replacement time. I've not done something like this before, so if anyone has any other details on repair, I'm all ears.
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