Wont shift into gear after full rebuild. First time completing full rebuild.

Discussion in 'Engine' started by Ckblaster, Jun 13, 2020.

  1. Ckblaster

    Ckblaster Member

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    Hi guys, I'm new to the blaster forum and decided to finally make an account because maybe I could get some help. I recently completed my first full rebuild
    on my 05 yamaha blaster. After putting it back together it fired up and sounded great, but when I tried to shift i hear the click but the bike won't move. It's as if it is in neutral. Not sure if it has something to do with the shifting mechanism or the transmission. Any help would be appreciated. Thanks
     
    Last edited: Jun 13, 2020
  2. Slydog

    Slydog Member Technician

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    Was the shift star bolted on or welded on? If bolted on. Was the locating pin installed Pryor to bolting on star?. Dum question but is shifter tight?. You may have to drain the oil and pull clutch cover to investigate.. Take some pics of shift shaft and shift star area . maybe we can see something wrong in clutch area. You hope
     
  3. Slydog

    Slydog Member Technician

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    What side did you split case from? If from clutch side. Shift fork numbers have to face down. Fork #1. On the. Bottom and #3 on top numbers down on long pin. #2 number down on short pin. With clutch cover off and rear tires supported off the ground turn tires and have someone try shifting while you watch shift shaft and shift star.
     
  4. blaster7

    blaster7 Member

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    I hate things like this, if something is incorrectly installed in the trans that means all new gaskets and a lot of time. I will attach some pics for for. Hopefully everything within your trans is correct. 29C701D4-3C9D-443B-A7B1-66ABA970617E.png E417833B-DD10-4397-A126-8F0EC885EB8A.png 2A31E2D4-71BA-4707-95BC-0FA5EFCDF699.jpeg
     
  5. Ckblaster

    Ckblaster Member

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    The
    I believe that the shift star was welded on, and yes the shifter was tight. I will upload some pics of the that area. Thanks
     
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  6. Ckblaster

    Ckblaster Member

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    Might have to split the cases, but I'm almost sure the transmission was put together right. Im learning the hard way right now lol. Thanks for the images above.
     
  7. Ckblaster

    Ckblaster Member

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  8. Slydog

    Slydog Member Technician

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    Check everything external first
     
  9. Slydog

    Slydog Member Technician

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    Looking at the pics . something seems off With the shift shaft. Was the shift shaft bent ?does it slide in and out of caseEasily. Push shifter up and it springs back down.Looks like it is stuck in the up shift position in a few of your pics
     
    Last edited: Jun 14, 2020
  10. Slydog

    Slydog Member Technician

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    If your motor is in the same stage of disassembly as pics.remove shift shaft. And locating arm with roller. Shift star point with notch is nuetral. Looking at pic your in 4 gear maybe?
    Turn main shaft by hand and star clock wise you should be able to feel it shifting gears it should be down shifting .have to keep turning main for it to shift.
     
  11. Ckblaster

    Ckblaster Member

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    I can easily pull the shift shaft out.... but when I try to shift it into gear it doesn't hook?
     
  12. Slydog

    Slydog Member Technician

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    It is not retiring to its middle position. Its staying in the up shift position. See the window with big spring close to where shift shaft goes thru case .shift shaft is bent? Or there is an issue with that spring.
     
    Last edited: Jun 14, 2020
  13. Slydog

    Slydog Member Technician

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    If you push shifter up and let go does it spring back down? Same thing down. Does it spring back up?
     
  14. blaster7

    blaster7 Member

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    He is indeed stuck in fourth from the pics. Sly is correct, if you manually shift while spinning the drive axle and it doesn’t shift then you have an issue. Now if like sly said and the shift selector paw does not return to center when you shift up or down then that could indicate an issue with the shift shaft/selector paw.

    Did you manually shift it after you got the cases back together? Did you check runout on the trans axles? And I would definitely check that shift shat for a bend as sly said because if there is a bend there it could cause this sort of issue as well, although I have seen them bent pretty good and still shift sometimes.
     
  15. Ckblaster

    Ckblaster Member

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    Ok I'll check it out tomorrow and let you know what's up with it.
     
  16. Ckblaster

    Ckblaster Member

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    Due to this being my first rebuild I did not realize I could manually shift before assembling the rest of the engine. Man I wish I would have known this before, but at least I do now.
     
  17. blaster7

    blaster7 Member

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    I think you’ll get it this time around, just take your time and don’t over look anything. I know it’s easy for me to say this because I’ve done hundreds of rebuilds and it’s second nature to me but I can understand how upsetting it can be to have to pull something back apart after it was just put together.

    You can even test shift it without the case half’s being together as per the service manual. I always do both, once before I put them together and then again after there together. I also check the runout on all of the trans axles just to play it safe. A good set of V-blocks and dial indicators go a long way with taking the guesswork out of knowing if something is straight or not.

    Another I think a lot of people over look is that the case half mating surfaces must be clean and spotless and only use three bond or yamabond 4 which is what I use. This way you know that the crank case is 100% sealed and should pass a leak down test.

    Hey, look at it on the bright side, at least you’ll know this engine up one side and down the other after all of this, so the next rebuild will be nothing for you.
     
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  18. Ckblaster

    Ckblaster Member

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    So I pulled off everything but the shift star, and I am able to turn the shift star counter clockwise from where the notch is pointed directly downward all the way to where the notch is pointing at roughly below 9 o clock. I'll post a pic or two. First pic shows shift star all the way clockwise and second shows it all the way counter clockwise. Does this help?
     
    Last edited: Jun 15, 2020
  19. Ckblaster

    Ckblaster Member

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    pic 1
     

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  20. Ckblaster

    Ckblaster Member

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    pic 2
     

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