KLR gear spline/shaft broken

[Dom_V8]

Hi all,
The other day while I was unloading my 199? klr 250 from a trailer the gear spline/shaft (part where the gear lever connects to the transmission) was snapped off clean. The previous owner had allready welded this spline back on but did a really shotty job of it, so now I'm stuck with the task of fixing in. From rough inspection it looks like that if I wanted to replace it, I would need to split the transmission case which is something I want to thoroughly avoid doing. The shaft is broken almost all the way up to the case and there is not much really left of it. Is there any other way to fix this problem without having to rip the bike apart?? Anybody heard any old tricks that could work? If I do need to pull the bike apart, is there anybody who could supply a damn manual that isn't in bloody german!!!! I will post up some pics of the broken parts tomorrow. Thanks in advance.

[stinkwheel]

Completely thinking out loud here, could you drill into the end of it, screw in a threaded stud and do the same with the broken bit. Screw them together with threadlock then get a wee spot weld put on to stop it unscrewing.

Do have a closer look though. Some Kawasakis have a seperate primary gearshift cover. The KLE500/GPZ500 definately does but it isn't immediately obvious. On those it's hidden behind the front sprocket.
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