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Shift countershaft stuck

  • RustiePyles
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Shift countershaft stuck was created by RustiePyles

I’ve been fighting this shift countershaft for quite a while, it’s rusted up pretty bad. I’ve tried PB Blaster, liquid Wrench, brake fluid & acetone, heat (map gas), currently have the cavity filled with Evapo-Rust. Anyone else fight this battle and win?
Fletch

1975 DT175B
1979 XS650
29 Aug 2020 09:51 #1

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Replied by MarkT on topic Shift countershaft stuck

That design was not one of Yamaha's better ideas...

What are you trying to do?
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
29 Aug 2020 10:03 #2

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Replied by RustiePyles on topic Shift countershaft stuck

Trying to split the cases.
Fletch

1975 DT175B
1979 XS650
29 Aug 2020 10:05 #3

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Replied by MarkT on topic Shift countershaft stuck

I'm sure I have nothing new to add but I use a large brass punch and tap the shaft with the arrow in pic below out after removing the clip and disengaging the "claw" from the shift drum on the other side of the engine.




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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
The following user(s) Liked this Post: Supergraphic, RustiePyles
29 Aug 2020 10:21 #4

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Replied by RustiePyles on topic Shift countershaft stuck

Evapo-Rust did the trick.
Fletch

1975 DT175B
1979 XS650
The following user(s) Liked this Post: yamahahaha, Supergraphic
29 Aug 2020 11:21 #5

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  • RT325
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Replied by RT325 on topic Shift countershaft stuck

Yep, certainly not Yamaha's best idea & would last better if the seal was left out so the gearbox oil filled that area as well.
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29 Aug 2020 14:31 #6

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Replied by RustiePyles on topic Shift countershaft stuck

I’m drilling and tapping the cover for a zerk.
Fletch

1975 DT175B
1979 XS650
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29 Aug 2020 14:39 #7

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Replied by Supergraphic on topic Shift countershaft stuck

How did you get the screws out? Mine seems stuck so I can't get that shift Shaft cover off...
been trying to use an impact driver to no avail.
16 Oct 2020 08:53 #8

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Replied by RustiePyles on topic Shift countershaft stuck

I didn't have any problems with those particular bolts, but I've had pretty good luck with PB Blaster, a little bit of heat from a propane torch, and an impact driver. Make sure your impact driver is driving the right direction, sometimes they can get reversed unbeknownst to the operator.
Fletch

1975 DT175B
1979 XS650
16 Oct 2020 10:13 #9

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