Well, I spoke too soon. Changed out the shifter shaft seal today and I think I pulled the shaft outward too much to expose the circlip groove and now the bike will only go into first gear. When I tried to push it back in a bit it now stays in and is now stuck in first gear. I think I can access the opposite side of the shifter shaft from the clutch side. Please someone tell me I don't have to split the cases to fix this!
Sorry to be such a noobie!
Roland

no but you have to remover the clutch cover and realign the teeth on the shift linkage behind the clutch  it will be obvious when you see it
doug

Just align the teeth central to its mate. Also be sure the return spring is in place & not hopped of & the ears got crossed. Then get around the other side & fit the circlip & washer or whatever goes on there so it doesn't slip back. After that you should be safe to fit the clutch cover but click it through the gears first just moving the bike a little back & forth to be sure it's safe.

The manual shows how to time the sector gears... picture from a similar model with gears completely disengaged.  Yours is probably off one tooth.

 



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Hi Guys,
Thanks for the help. I have the shifter teeth put together fine now, but it does not shift properly at all. I am sure the shifter needs to be adjusted. But I will tell you I see no way of measuring the gap between teeth and making that adjustment, at least not on this model. I am beside myself to be honest. I caused this mess and now have to correct it. 
Any advice on how to adjust the shifter would be helpful.

If it was ok before then won't need adjusting now, so thinking cap on. Have you removed the detent plunger underneath on the left side. There 'is' an adjustment No11 for minor centralizing. The spring it sitting square on ok i hope. Can't go wrong unless it hopped off & got its ears crossed. You can see in the drawing how it should sit straight on No11, spring being No9.
www.partzilla.com/catalog/yamaha/motorcy...974/dt360a/shifter-2

Not sure what you mean by measuring teeth gap. Forget about that. Just sit it equally like i think Mark drew to show how when mated up it looks even--central. Keep coming back please as we're all keen to get you sorted.

I had same issue when I first got mine and issue was two sector gears got moved out of place with clip on L side is off and then put back together without confirming sector gears are centered.

did it properly shift prior to assembly to replace the seal?

is the ratchet thing (on shifter 2 in Partzilla parlance) riding over the pins of the drum when you move the shifter up and down?  Does ratchet hook pins? 
Can you see shift drum (pins attached to it) turn at all?

 Other adjustment I remember was setting adjustment to approximately center ratchet over pins. If bike shifted before seal episode then IMHO adjustment is not issue.

might want to recheck that the sector gears are centered per pics i think someone already sent and that clip and washer are on after doing so.

Just talking that adjustment screw if you 'had' to alter it just hook it into say third gear to get away from neutral half movement. Then when in gear if you hand felt the gear lever you should have approx equal up & down movement before it hooks the next pin on the drum. So might be 10mm springy feel up & down at the tip of the lever before touching & turning the selector drum.
Also, to get it to change up or down you'll need to move the bike fractionally. If you imagine sliding fingers of one hand into another & they come up end on then you need to move about that much to get them to slide in.

Hi Guys,
So had to remove the assembly as someone overtightened the F%$%#@$K out of it. I corrected and reinstalled it and have freedom to make a wide range of shifter adjustments. The spring is in the proper place but it is always centered as it is tight around the pivot pin. I can now go through all gears, but will continue to perform fine adjustments so there are no catches anywhere. Then I will lock it down. The system works well, but to be able to actually measure how centered the shift forks are on the shift pins is impossible IMO. I will go for the smoothest shifting and leave it. 
Will let you know how it goes.
I should have known that once I removed that clip on the shift lever side to replace the seal not to let that shaft get pushed in.