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

[richinar]

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]

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 Ease the plate out and then the shifter can be withdrawn through the right side.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]

Good for you for jump in and getting this fixed

[JerryHawk250]

It would be a good time to clean out the centrifugal oil filter while you have the cover off.

[richinar]

Good point I did remove the three screw cover found a need for a special socket to go further in that direction. However it was super clean inside.
BTW this rig has 1600 miles on it now - about 90-100 hours

[JerryHawk250]

Originally Posted by richinar

Good point I did remove the three screw cover found a need for a special socket to go further in that direction. However it was super clean inside.
BTW this rig has 1600 miles on it now - about 90-100 hours

If you have the stock Speedo it is in kilometers so roughly 1000 miles. I know .

[richinar]

??
Stock cluster indicated MPH until 365 miles when I upgraded to the digital with tach that you have. I’m quite sure the milage is accurate. hours mentioned as a correlation with dirt bike use to add insight into wear observed on spindle.

The Hawk had a lot of wear, IMHO. While both stock and Honda spindles were the same (less than .01mm as measured with POS digital caliper 3x) the Honda had a slightly firmer and smoother feel going through the right side bushing - that nice solid feel.

After a 20-mile shakedown everything was still right and proper with a tighter feel at the pedal, but that’s probably a red herring or placebo talking.

[JerryHawk250]

Originally Posted by richinar

??
Stock cluster indicated MPH until 365 miles when I upgraded to the digital with tach that you have. I’m quite sure the milage is accurate. hours mentioned as a correlation with dirt bike use to add insight into wear observed on spindle.

The Hawk had a lot of wear, IMHO. While both stock and Honda spindles were the same (less than .01mm as measured with POS digital caliper 3x) the Honda had a slightly firmer and smoother feel going through the right side bushing - that nice solid feel.

After a 20-mile shakedown everything was still right and proper with a tighter feel at the pedal, but that’s probably a red herring or placebo talking.

Yes the stock cluster indicated an inaccurate MPH but the odometer indicated an inaccurate kilometers. lol The digital cluster is one of the best mods I have done.
Glad the Honda part worked out. I wonder how many other Honda engine parts will work on the hawk?

[richinar]

It took two days to receive a response from Ricky’s and TXpower has not yet responded on their capacity to provide a part. Unsettling to say the least. However, with the collective heft of this board’s members, blessed in astute reasoning skills, this hopefully short-lived dearth of support can be overcome.

Thank YOU for the great support.

[Sport Rider]

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]

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.