So my son crashed his KLX110 and broke the shifter off which still has the shaft tip in it. I did this when I was a yung-un' and I remember having the local farmer weld it back on for us. It broke off again and after the second try it stayed. The shifter never could clamp well after that because the splines got weld splash. We had drilled a hole down through it all and hammered in a roll pin, which broke a couple times...
In an attempt to avoid all my previous hassles, does anyone have any advice. I'll do a little research on replacing the shaft but I can't image I want to go that route. Would a TIG weld be a better option than the wire feed we used back then? I know I've noticed they seem like cleaner welds. I've no experience welding so pardon the ignorance.

 

Aw man, take the time and do it right. Welding is likely going to cook the shifter shaft seal and then you have that issue to deal with. Also buy a good aftermarket folding tip shift lever.

Here is a link with steps, no pics though.

How to Replace the Shift Star in a KLX110 | eHow.com

 

It could cause a problem with spliting the cases if the need for that should ever arise. I suppose the weld on the shaft could be ground if need be.

I've heard of people welding the shifter to the shaft. Then later having to cut through the shaft to get the engine apart.

 

I would say you need to go find that old farmer. (sorry couldnt resist)

 

New shaft it will be! Turns out I won't have to split the cases. And I guess now is the best time to convert it into a manual clutch. And I also found out it might have a 4th gear that isn't used when auto clutch and the 05 shaft is much beefier and will be a direct fit. Thanks for the push!

 

My friend has a KLX110 also. We were surprised to learn that it has a hidden 4th gear inside. And you can just swap for a clutch case.