Trouble Shifting past 2nd gear

Josh263

New Member
Sep 27, 2014
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Hey guys, I'm new here and I'm new to Blasters as well. Thanks in advance for any help. My buddy and I were looking for a project and we recently purchased 2 old blaster that were not running. We rebuilt the top ends and were able to get the first one running. During our initial drive we noticed a few issues. First the brakes are absolutely horrible. Second thing is that I was having trouble shifting past second gear. I was able to get into 3rd once, however I didn't want to push it b/c the brakes. When I stopped, we tried to shift through all of the gears with the bike off. We could not get past second. When I am in second gear if I go to shift up it just clicks and the shift star does not turn. I took off the clutch and basket to get a better look. I tried turning the shift star with a screw driver this worked and I got to 3rd gear. I turned the wheels a bit and was eventually able to get through all the gears, and then back to neutral. I noticed that when I turned the screwdriver and the shift star did not turn the full rotation, if i twisted the rod that the clutch basket sits on counter clockwise, the shift star would finish the rotation and shift into gear. Does anyone have any ideas what might be causing the trouble when I try to shift. Also, on the second motor, we seem to be having a similar issue. Could this be an issue with the clutch not being tightened properly? I am attaching 3 videos so you an see whats happening.

In the first video, the clutch is still on and we are trying to shift.
https://drive.google.com/file/d/0B54NYEFbhqBiV0htdkhqS0pjY28/edit?usp=sharing
https://drive.google.com/file/d/0B54NYEFbhqBiV0htdkhqS0pjY28/edit?usp=sharing

https://drive.google.com/file/d/0B6ZPgHCQrZPRbkZOS0VRclVuNVE/edit?usp=sharing

https://drive.google.com/file/d/0B54NYEFbhqBiMmVjNzlCTmkyNTQ/edit?usp=sharing
 
Basically the way the gears and shift mechinism is designed, one or both shafts have to be spinning. As to the one that's running, might be bent shift shaft, worn springs on external shift mech, worn pawl/pins on star, bent or worn fork :)() , wrong/low oil.
 
In the 2nd video, what you are calling 2nd, is really 1st, so of coarse it won't downshift below 1st. Looking at the shift star, it turns counterclockwise to upshift.

It's perfectly normal for it to not shift with the gears stationary. Here is a pic of a Blaster transmission. You can see that if the dogs don't line up, it's not going to go into gear. That's why when you kill it or shut it off in 4th gear, you have to rock it back and forth to get it down to 1st and then up to neutral.

y-30568-yamaha-blaster-200-transmission-gear-set-yfs200.jpg
 
The shift fork pins could also be out of spec. The drum guides that the pins run in could be out of spec also. But I'm leaning towards a bent fork.