Transmission problems

[cole454]

I had to split my cases to reseal them. Now the blaster won't move. It'll go forward a few inches then stop and it will kill the engine. It seems like something is not turning right? :-/
Also now the only way to get it to roll is to have it in neutral and the clutch pulled in. Any other gear and the clutch pulled in, it will not move. Just neutral by itself and it won't move. Has to have both.
I'll be tearing back into it this week, just seeing if there's something to look for.

 

[cole454]

Any ideas?
Thanks

 

[Surfrjag]

somethings binding up. hard to say what it is. youwill have to take it appart slowly and inspect everythings movement. let us know what u find out!! did the crank turn freely when you put it together?

 

[cole454]

Will do. Hoping its something simple. I'm dying to ride.

 

[sicivicdude]

shift drum and or forks are installed incorrectly and it's trying to go into two gears at the same time.

 

[cole454]

I didn't remove any of the transmission. Could it have gotten misaligned without taking it out? And it worked before I redid the seal.

 

[DUALSTROKE]

shift drum and or forks are installed incorrectly and it's trying to go into two gears at the same time.

^^^^ my thoughts exactly.Good info!!!

I didn't remove any of the transmission. Could it have gotten misaligned without taking it out? And it worked before I redid the seal.

The shift forks can fall out of place easily enough and most likely what happened.I will mock up a set with pics for you and post them later if you need me to.

 

[cole454]

That would be awesome.
Thanks

I have a service manual, but the pics are horrible + not too many of them. I'm a picture/visual kind of guy. lol
I ordered a clymer manual after I heard they are much better for diy.

 

[sicivicdude]

The shift forks are on their own shaft and even inadvertantly can become mis-aligned if the shaft slipped out long enough for one of the forks to fall out of the drum and then you stuck it back in without noticing the fork was not engaged in the groove on the drum. The free fork and drive dog you be trying to lock the main and counter shaft into one gear while your drum is trying to put the two shafts into another (the correct one).

Just need to pull it back apart and check everything over real well. Use pic dually provides and the manual to work your way through the shift forks and drum to make sure everything it working.

On a side note, that's one reason I check the transmission operation immediately after seating the two case halves together. I don't even give the yamabond time to dry before I slide the shifter on the shift shaft and turn the input shaft to make sure it has all the gears and doesn't bind. Just one bottom end where a gear is binding is worth the time taken to do this to each bottom end that goes together...

 

[cole454]

Will defiantly check the operation this time. Thanks

 

[sicivicdude]

You'll probably pop it open and find a shift shaft out of it's place. Pop it back in and it'll be fine just make sure you check it before you put it all back together again. Much easier to resplit freshly bonded cases on the workbench than it is to pull everything back apart once it's in the quad and it doesn't work. Good luck!

 

[cole454]

Yeah, I know that. I had to resplit them once already because I forgot the balancer. :-[

It was 2:30am in my defense. lol

 

[DUALSTROKE]

 

[scotj77]

good pics of one dirty tranny . lol

 

[DUALSTROKE]

 

[DUALSTROKE]

 

[DUALSTROKE]

If you need more let me know.The flash got in the way of a few,lol

 

[DUALSTROKE]

good pics of one dirty tranny . lol

I just grabbed one of the spares and tossed a mock up together for him to have some reference pics.No cleaning included!!!lol Hell the job wasn't even long enough to get through 1 beer.

 

[cole454]

Thanks much for the pictures. They will help a lot.

 

[cole454]

How difficult should it be to spin the inner clutch basket when testing the tranny? I have it back together and it goes through all the gears, but it seems stiff when turning the basket.