[Oliver_Vallberg]

Hi, I’ve got an issue with my bike not shifting.. it’s stuck in what i believe to be 2nd gear and it starts and runs just fine until you’re trying to shift gears. If I try to go down like I would shift to 1st the gear ”lever” is just solid in place, it won’t move the slightest bit. However when I go into third the rear wheel just locks up even though the engine is still running with the clutch engaged.

If you or someone you know have had the same problem please let me know so I know what to expect when I split the cases. The right thing to do would probably be to take it to Yamaha and let them have a look I know, simply can’t afford it right now.

All tips are appreciated!!

 

[NorthCust]

first: what year/gen bike is it?

I've not had the same problem but I have recently rebuilt the engine I'm running currently. Splitting the cases (and more importantly getting it back together again and working) was no small task and required some special tools (e.g. to very carefully pull the crank/bearings into place). Have a look on my website, I posted a bunch of pics of the internals whilst rebuilding it.

I suspect taking it to yamaha to fix would be horrendously expensive.

So just to check I've understood it right - you can start it up (presumably with the clutch pulled in) and when you release the clutch it rides as it should (wheels go round etc), but you can't shift down to first/neutral at all and if you shift up the rear wheel locks altogether?

 

[Oliver_Vallberg]

first: what year/gen bike is it?

I've not had the same problem but I have recently rebuilt the engine I'm running currently. Splitting the cases (and more importantly getting it back together again and working) was no small task and required some special tools (e.g. to very carefully pull the crank/bearings into place). Have a look on my website, I posted a bunch of pics of the internals whilst rebuilding it.

I suspect taking it to yamaha to fix would be horrendously expensive.

So just to check I've understood it right - you can start it up (presumably with the clutch pulled in) and when you release the clutch it rides as it should (wheels go round etc), but you can't shift down to first/neutral at all and if you shift up the rear wheel locks altogether?

Yes you understood me correct. It’s a -08 bike, And yes I know I’ll need some special tools although, I’ll try to freeze the bearings and heat the engine case with a blow torch before I barrow the right tool from a friend since the method with a blow torch worked just fine on my old AM6 DT50 engine that I did a rebuild on.

Thanks alot, I’ll definitely check out your page regarding the engine!
Much appreciated!

 

[Oliver_Vallberg]

first: what year/gen bike is it?

I've not had the same problem but I have recently rebuilt the engine I'm running currently. Splitting the cases (and more importantly getting it back together again and working) was no small task and required some special tools (e.g. to very carefully pull the crank/bearings into place). Have a look on my website, I posted a bunch of pics of the internals whilst rebuilding it.

I suspect taking it to yamaha to fix would be horrendously expensive.

So just to check I've understood it right - you can start it up (presumably with the clutch pulled in) and when you release the clutch it rides as it should (wheels go round etc), but you can't shift down to first/neutral at all and if you shift up the rear wheel locks altogether?

Also, it would mean the world if you could give me a list of every bearing/seal that would need to be replaced. The bike doesn’t have that many miles on it (1,4k) however it’s probably smart to change pretty much every wear item while I’m in there. So the next owner will have a good running bike since I’m gonna upgrade pretty soon.

 

[NorthCust]

Also, it would mean the world if you could give me a list of every bearing/seal that would need to be replaced. The bike doesn’t have that many miles on it (1,4k) however it’s probably smart to change pretty much every wear item while I’m in there. So the next owner will have a good running bike since I’m gonna upgrade pretty soon.

lmao I wish I was that organised. It took me a bunch of orders off MSP and other places before I finally had all the bits together. I have someone I use for bearings and engine internals and can pass you on their details. drop me an email to [email protected] and I'll see what I can find.

But yes spltting the cases is a royal pain in the ass so replace as much internal stuff as you can afford whilst it's open. I seem to recall there was 6 additional bearings to replace as well as the main crank bearings, and tbh my only regret is i didn't put a racing gearset in too while I had it in bits so that it was all new inside, but hey I didn't have infinite budget or time.

Thing is even replacing the main bearings (properly) is not a trivial task. I made a video on my first attempt to remove the lower timing gear (which failed miserably) nad whilst I got it off in the end and have also since I learnt of a better method, even that relies on having a press too, nevrmind truing the crank once you've pressed it all back together. It's all doable and I learnt how to do most of that stuff most of it from your countryman 2strokestuffing's excellent videos,...but don't underestimate the depth of the rabbithole.

My last few videos cover much of the process for the R125 but, in my case at least it involved making special tools to do the job: press plates from 8mm steel, a crank truing stand and a tool to pull the crank into position once built.

Presumabyl you have a copy of the service manual already?

anyway I'm sure we can chat more by email, I'm happy to share what I've learnt