Fixing part 39110 (Tie Rod)
Thank you all for your replies. I was able to get the rod (pn 39110) in without splitting the case open with the help of my father in law " The great one " with removing clutch and stator and of course it being a 2 man job and A LOT of patience was able to remove the broken rod from a small hole on the stator side using a ratchet w/extension (That was the easy part) replacing the new rod was a bit difficult but we managed to get it in using a rubber hose inserting it from stator side while helper #2 holds pn13161 in place from clutch side (we used an old wire hanger) the nuts on the rod were set prior to replacing, with only the shifter side having put lock tight. once the rod was screwed into pn13161 we unwound it (using a flat head srewdriver) almost to the point it would fall out (keep in mind counting every 1/4 turn) the whole assembly with pn13242a was disconnected from the motor for easier accessability. Now here is why we had to keep count of how many turns we unwound it because it took us a few tries just to get it to screw into pn13242a. once we got the rod in, using a wrench tightened the nut on pn13161 first (because it had the lock tight) then tightened pn13241a last and used lock tight. At this point the assembly was put back in place and we checked to make sure it could shift through all the gears before putting the clutch and stator back together. It was a long road getting a $7 part in without splitting the case but it is possible. why you might ask did we do it ourselves? well the bike cost me $500 (Hence it was broken) to own it, the shop wanted $2000 to do the job (minimum cost) also the only place that had an engine where im at wanted $1800. I could have bought a whole bike that worked for the price to fix this one. The bike was put back together and taken out for a test drive, it shfts with ease through all gears with no problems. So it is possible to do it without splitting the case open but it will require time, patience and a little bit of Macgyver Mechanics to do. I hope this might help someone who has had the same problem as me and cant afford to send it to the shop.
Last edited by bigpakapump; 07-27-2011 at 05:36 AM.