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Question This cannot be good!?

  • msavitt
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Replied by msavitt on topic This cannot be good!?

Thanks for the addition suggestions and thoughts, I will run these down today. A bit more info:  when I said clutch “in” meant disengaged; clutch “out” (when noise occurs when riding) means engaged. 

when I did ride it I shifted up and down all 5 gears and neutral, albeit while never exceeding 5 mph. I wanted to get this data but didn’t want to chew up whatever sounded like it was chewing !

thanks again gents - I am going to check starter assembly against schematic and other suggested items  more info to come. 
24 Nov 2021 07:49 #11

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Replied by RT325 on topic This cannot be good!?

Ok, just to add--"i keep adding sorry"--clutch in or out the three kick gears are still revolving spun by the clutch drum direct from crank. So on the face of it--it sounds like problem will--or might--be internal. But if you got through 5 gears & back to neutral--i don't know. Might be three gears i can think of that could be fitted back to front but i feel the dogs wouldn't engage enough for the drum to revolve to the next gear. 25--23--& 7 in the link. I'll stop annoying you now & hope i'm very wrong.
www.partzilla.com/catalog/yamaha/motorcy.../dt400e/transmission
24 Nov 2021 12:44 #12

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Replied by msavitt on topic This cannot be good!?

Hey RT, thank you and others. 

so I studied this mechanism and the manual and what I learned is that the kick idler and the kick gear are always engaged. And I do believe - could be wrong - that the missing / wrong parts (26, 277 are designed to move the ratchet 21 out axially so once running the kick gear rotates smoothly vs click click click which I think is my issue…or my sincerest hope!  We will soon see 
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24 Nov 2021 13:38 #13

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Replied by msavitt on topic This cannot be good!?

Check out my big miss and what I believe caused my mystery noise in this video

I didn’t closely inspect the trans after cleaning it because the gears looked so good. As you can see the output shaft has issues; 1st has like 1mm of slop due to a burnt bushing and 3rd not much better. Next time I complete disassemble transmission so that I can really see and feel what’s going on which I think is more difficult to do assembled. 

I decided to keep things cheap and easy so I bought a nice looking complete transmission set for <$30 on eBay that reportedly ran when parked. 

So that’s my noise and my mistake. I hope that I am buzzing around before Christmas, which was the plan all along. 


 
02 Dec 2021 18:59 #14

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