Background: 2004 500FK- Did a full engine rebuild and now I have a part that was with the shifter assembly parts with no home.


I have a push rod/pin of some sort that is 6x26mm but I cannot find a place that it goes. I cant remember where it came from. It seems to be the same exact cut and material of the clutch push rod (the one that goes into the counter shaft cover). I cannot find a part number OR a diagram that includes it.

PHOTO: https://imgur.com/gallery/Fr1Vy
-The part in question is in the caliper while the clutch push rods are below for comparison

I THINK its number four. as the other two are clearly 20 and 19 in the picture below. but it looks kinda fat and kinda short compared to mine.. MAYBE it could be Number 17 on the second image blow this? does it fit there? is there something already there?

I doubt it's 17, that looks like the key for indexing 16.  The part in question is at least two times too long to be 17.


It also seems way too short to be 4, no way three shift forks are going to fit on an inch long rod.
Seems really hard to forget that piece, as well...

JWalker what planet are you on?! 
17 is a lever, nothing like the pushrod in gearhead's imgur picture.
And number 4 is a nut! We're trying to ID a simple short rod aren't we?

Could that be 20, the shorter part of the two-piece central clutch pushrod?
(I can't remember mine now).
I may be way off beam though.

Jools, I think when Walker said #4 he meant in to top picture he posted (the dog shaft?).

Thanks for the replies guys, I can confirm that it does not belong to either of the parts diagrams above. I already put the motor together and this small part does not fit in with the others. I repeat, everything goes together without this little piece and does not go together with the piece. I am surprised I let a part go rogue on me like this.

Are you sure it's even related then?  Could be a pin from another project that was on the workbench at the time, or something.  It looks really clean.

Quote from: Big Rich on April 27, 2017, 01:44:57 AM
Jools, I think when Walker said #4 he meant in to top picture he posted (the dog shaft?).

yeah sorry the first picture, part number 4, its the shaft that slides into the outside of the case [behind the front sprocket] outside in.

Quote from: Watcher on April 27, 2017, 09:50:49 AM
Are you sure it's even related then?  Could be a pin from another project that was on the workbench at the time, or something.  It looks really clean.

I wouldn't rule that out, although I've checked every exploded view and manual I have access to, it could belong to another part of the bike. I've had every piece apart, and back together. I did my best to keep everything together in its respective category.

What planet am I on!!! 

That looks exactly like the spacer I purchased from Ace Hardware to remove the starter clutch/generator rotor assembly. You put it in under a bolt and it pushes the assembly off. Any chance you used it for that and then forgot?

What about part 8 or 9 in the first pic?

Quote from: Bluesmudge on April 27, 2017, 04:20:56 PM
That looks exactly like the spacer I purchased from Ace Hardware to remove the starter clutch/generator rotor assembly. You put it in under a bolt and it pushes the assembly off. Any chance you used it for that and then forgot?

Nope, cause i actually made that part by cutting a bolt and grinding the threads down.