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Re:DT250 - Stuck in gear

12 Jul 2020 22:43
david.martin
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Re:DT250 - Stuck in gear #1
Hey guys,

after reviewing the thread below I took the cover off, removed the basket and can see the selector but now I am stuck to understand what might be jamming the box in gear.
The bike will turn (with and without basket on i.e. the gear box turns nicely) just stuck in a gear (not sure which one!)

Any ideas?


:https://www.yamaha-enduros.com/index.php/forums/general-discussion/10011-dt400-stuck-in-gear-after-changing-shifter-seal?start=10

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13 Jul 2020 06:01
RT325
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Re:DT250 - Stuck in gear #2
If its been full of water it could be one or all of the following. Cam plate plunger rusted to the hollow bolt ir slides --left side underneath at an angle. Selectors could be rusted to their respective shafts. Selector pins rusted into the selector drum. Things like that--or gears rusted on the shafts & not wanting to move sideways. Pull the bits out you can see there & grab the end of the drum firmly but carefully if that's possible & see if it'll crack free. Remove the cam plunger & spring first though.
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13 Jul 2020 11:55
david.martin
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Re:DT250 - Stuck in gear #3
Thanks! Yes pulled the plunger/shift stopper and it was jammed but down in its bolt.

I’ll try and turn it manually.

Any ideas where to source a shift spring from?


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13 Jul 2020 12:14
run103
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Re:DT250 - Stuck in gear #4
looks like you should be splittin the cases. easier now than after you spend money and the seize a transmission shaft
Just talkin Doug
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13 Jul 2020 12:16
david.martin
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Re:DT250 - Stuck in gear #5
Yes, I’m only a few bolts away really!
Ok. I’ll strip her down. As you say, piece of mind.


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13 Jul 2020 12:47
run103
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Re:DT250 - Stuck in gear #6
looks like you should be splittin the cases. easier now than after you spend money and the seize a transmission shaft
Just talkin Doug

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13 Jul 2020 15:25
apex
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Re:DT250 - Stuck in gear #7
I had a Suzuki TS250 once that had water in the transmission, and the shift drum (iron) rusted and was seized in the case. Could be your issue too, was easy enough to free up & clean, didn't have to replace anything!

Allrighty Then
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13 Jul 2020 15:33
david.martin
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Re:DT250 - Stuck in gear #8
But you had to split the case for that, correct?
Good thing with these motors as the gearbox side is less complex than its smaller cousin (175)..... word of wisdom... never take anything apart if you don’t intend on putting it back together within the same year :/


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13 Jul 2020 16:38
MarkT
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Re:DT250 - Stuck in gear #9

david.martin wrote: But you had to split the case for that, correct?
Good thing with these motors as the gearbox side is less complex than its smaller cousin (175)..... word of wisdom... never take anything apart if you don’t intend on putting it back together within the same year :/
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Interesting comment... I've always thought the 175 was easier than the 250/360/400! :) (It might not be, the layout with the shift drum above the trans just makes more sense to me maybe?)

And yes, great advice... taking lots of pictures is a great idea too! Unfortunately taking pictures is not a habit I've really gotten into... used to be an expensive hobby and when I grew up, pictures were only taken on very special occasions.




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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

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13 Jul 2020 19:45
apex
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Re:DT250 - Stuck in gear #10

david.martin wrote: But you had to split the case for that, correct?
Good thing with these motors as the gearbox side is less complex than its smaller cousin (175)..... word of wisdom... never take anything apart if you don’t intend on putting it back together within the same year :/


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Yes sir, case split.

Allrighty Then
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