How to Repair a Bent Shift Fork
One thing that can really throw off your shifting while driving is when you bend your shift fork. It can happen like this or by having an excessive amount of force placed on it from one general direction causing impact. A shifter is very difficult to bend, however it still can happen. The ease of repairing or replacing it depends on how badly it is bent and the makeup of the material structure. If you're not afraid of messing with the transmission, replacing a bent shift fork should not be a problem. A transmission is very straightforward to work on if you have mechanical knowledge and the owners or Chilton's manual for your vehicle. This includes motorcycles, or any other manually shifted transmission.
Step 1 - Drain the Oil and other Coolants
The first thing you will want to do after the vehicle is secured so that it won't move, is drain the liquids from the transmission. Once you have the oil drained and properly disposed, start disconnecting any wires or cables that run along the side of your transmission, that might get in your way during the maintenance.
Step 2 - Gain access to the Transmission
Next you will want to disconnect the transmission from the drive shaft and set it to the side. You will need to drop the transmission so that you can better access the shift fork inside the cam case. Use your four jacks, and the four 2x4 planks to hold the transmission in place while you disconnect it. This is preventing it from dropping to the ground when its removed causing internal damage. You can lower it onto the rolling board and get it out from under the vehicle. Some transmissions are not that heavy, if that's the case the planks and the jacks may not be needed.
Step 3 - Accessing the gear Box
Get the transmission to your work table with some assistance from a friend with a good back or an engine hoist. This way you can begin to open it up to gain access to the cam to change out your shift fork. Be sure to organize your nuts and bolts organized in small dishes or baggies. There is nothing worse than having leftover parts once you are done.
Once you get the transmission open you should see that the fork is now accessible. Once this is opened you will see the shifter fork right in plain sight. Look around for gears or cogs that may be damaged or broken and replace those as well. Install your new fork and reverse the process to get the transmission back into place.