This is a copy of a post I just made on yamahaenduro.com - but I figured maybe someone here may be able to advise
Hey everyone,
I've been working on a 1975 DT400 engine for a while now.
Every time I join the cases, I can't shift gears. It's stuck in a gear. The shift drum has a few degrees of loose play and then its solid on either end.
I can rotate the output shaft all day while trying to turn the shift drum, but it won't budge.
This is my 2nd time splitting the cases, going through the transmission parts diagram, making sure it works, then joining the cases. Before the cases go together, it shifts through all the gears as I rotate the output shaft. I can't seem to replicate the problem with the cases split.
I noticed this time, while splitting the cases after another failed attempt, that it begins shifting gears once the cases are split a quarter inch or so.
Does anyone have any words of wisdom? Am I missing something basic, or has anyone else ever experienced this?
When the urge to drop kick the bottom end subsides, I'm gonna remove the left side crank bearing so I can mate the cases temporarily to try to figure out what's happening.
Hey everyone,
I've been working on a 1975 DT400 engine for a while now.
Every time I join the cases, I can't shift gears. It's stuck in a gear. The shift drum has a few degrees of loose play and then its solid on either end.
I can rotate the output shaft all day while trying to turn the shift drum, but it won't budge.
This is my 2nd time splitting the cases, going through the transmission parts diagram, making sure it works, then joining the cases. Before the cases go together, it shifts through all the gears as I rotate the output shaft. I can't seem to replicate the problem with the cases split.
I noticed this time, while splitting the cases after another failed attempt, that it begins shifting gears once the cases are split a quarter inch or so.
Does anyone have any words of wisdom? Am I missing something basic, or has anyone else ever experienced this?
When the urge to drop kick the bottom end subsides, I'm gonna remove the left side crank bearing so I can mate the cases temporarily to try to figure out what's happening.