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Makotosun

DT360 2nd gear problem

  • peteyam54
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DT360 2nd gear problem was created by peteyam54

My DT360A will not shift into 2nd gear. It was previously perfectly OK, but now it will go into 1st fine but will not engage 2nd gear (feels like the lever is not even connected). Neutral is OK though. Any ideas before I start stripping it down? Thanks. Pete
12 Feb 2022 09:42 #1

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Replied by msavitt on topic DT360 2nd gear problem

Hi there
Did you have the clutch cover and/or the clutch off or apart?
It is likely that the two sector gears that connect things up are not indexed properly, making this an easy fix...I have done this several times!

Hi there
Did you have the clutch cover and/or the clutch off or apart?
It is likely that the two sector gears that connect things up are not indexed properly, making this an easy fix...I have done this several times!


  
 
12 Feb 2022 15:09 #2

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Replied by RT325 on topic DT360 2nd gear problem

I'm with MSAVITT above. Should be engaged centraly on the teeth.
Actualy it could bugger up if for some reason the circlip popped off while having the gearlever off or having to knock it too hard to get it back on the splines. Circlip #5. & if ya lucky--very lucky--might be able to save the situation by pushing it back & manipulating it a tooth but be lucky if you can do it without the return spring hopping off & getting cross legged.
Last edit: 12 Feb 2022 16:04 by RT325.
12 Feb 2022 15:57 #3

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Replied by Schu on topic DT360 2nd gear problem

Hopefully MSAVITT is correct, but I had the exact same issue on my DT400B and wasn't so lucky. The link below describes why mine would go into second.

yamaha-enduros.com/index.php/forums/1977...gear?start=10#125717
Schu

CT1B, CT1C, JT1, JT2, CT2, RT3, DT360A, GT80B, DT100B, DT125B, DT175B, DT175C, DT250B, DT400B, Z50

Someday, you'll own some Yamahas
12 Feb 2022 17:00 #4

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Replied by RT325 on topic DT360 2nd gear problem

Ooh & Oh, yeah i remember that.
12 Feb 2022 17:28 #5

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Replied by msavitt on topic DT360 2nd gear problem

Broken gear would suck 
13 Feb 2022 09:04 #6

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Replied by MarkT on topic DT360 2nd gear problem

"feeling like lever is not connected" sounds like hopefully its a linkage issue.

Picture of similar sector gear timing marks (arrows) and what it looks like when completely disconnected.  Can also jump a tooth sometimes...  was bike dropped or took a hit on end of shift shaft?  Recently replaced seal?  E-clip under shift lever missing?  Those are most common reasons sector gears jump.  Pretty easy fix... 

 



 
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
13 Feb 2022 10:01 #7

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Replied by msavitt on topic DT360 2nd gear problem

pull the clutch cover!
13 Feb 2022 11:39 #8

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  • peteyam54
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Replied by peteyam54 on topic DT360 2nd gear problem

Thanks for the advice, I've now got it sorted.
The problem was the teeth on the gearchange levers had moved by one tooth. The previous owner had left off the washer under the gearchange lever, so when I pushed the gear lever back on, there must have been enough play to push the lever out.
Easy fix - thanks for the help, I was worried that I might have to split the cases!
The following user(s) Liked this Post: MarkT, RT325, msavitt
13 Feb 2022 11:40 #9

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Replied by RT325 on topic DT360 2nd gear problem

Is the circlip still there as well as the new washer. Pity Yamaha didn't add an internal stop to the clutch cover case as wouldn't take much in design.
13 Feb 2022 15:19 #10

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