YZ250 Shift Shaft replacement - '06 2-stroke

Falcon
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Falcon
Edited Date/Time 8/10/2020 2:15pm
New territory for me. I sheared off the end of my shift shaft today. Can I just R&R it from the right side, or do I have to split the cases? There is a collar, a spring and a washer on the shaft according to the diagram and I can't tell if they go on the clutch side or the magneto side.

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Falcon
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Falcon 8/1/2020 6:07pm
8/1/2020 6:07pm
Oh sweet. Thanks!
captmoto
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captmoto 8/1/2020 8:30pm
8/1/2020 8:30pm Edited Date/Time 8/1/2020 8:31pm
At about 9 minutes he gets into pulling the clutch and shift shaft out.
Don't forget a new shift shaft seal.
FWYT
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FWYT 8/1/2020 9:16pm
8/1/2020 9:16pm
How did you break that, just out of curiosity?

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40
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40 8/2/2020 6:25am
8/2/2020 6:25am
While you have it apart, install the redesigned shifting cam stopper lever. Yamaha part STOPPER LEVER ASSY
BF1-18140-00-00. This part offers an improved bearing design.
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FGR01
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FGR01 8/3/2020 1:02pm
8/3/2020 1:02pm
40 wrote:
While you have it apart, install the redesigned shifting cam stopper lever. Yamaha part STOPPER LEVER ASSY
BF1-18140-00-00. This part offers an improved bearing design.
This. Make sure you replace the shift stopper if it hasn't been already. If your 2006 still has the original one in and it hasn't broken and scattered ball bearings in the trans you have been lucky.
Falcon
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Falcon 8/4/2020 8:44am
8/4/2020 8:44am
FWYT wrote:
How did you break that, just out of curiosity?
I rode it for 14 years. Wink
It broke on a downshift from 3rd to 2nd in some braking bumps. Probably a combination of fatigue and stress. I don't step off my pegs when I use the shifter, but there was still a lot of weight on it, I'd guess.
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Falcon
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Falcon 8/4/2020 8:45am
8/4/2020 8:45am
captmoto wrote:
At about 9 minutes he gets into pulling the clutch and shift shaft out.
Don't forget a new shift shaft seal.
Thanks for that.
Falcon
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Falcon 8/4/2020 8:47am
8/4/2020 8:47am
40 wrote:
While you have it apart, install the redesigned shifting cam stopper lever. Yamaha part STOPPER LEVER ASSY
BF1-18140-00-00. This part offers an improved bearing design.
FGR01 wrote:
This. Make sure you replace the shift stopper if it hasn't been already. If your 2006 still has the original one in and it hasn't broken...
This. Make sure you replace the shift stopper if it hasn't been already. If your 2006 still has the original one in and it hasn't broken and scattered ball bearings in the trans you have been lucky.
I'm pretty easy on transmissions, so I'm not worried. I will check that part out, though. Might as well while I'm in there. Going to put in some new clutch plates and inspect everything as well.
Falcon
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Falcon 8/8/2020 2:59pm
8/8/2020 2:59pm
Any creative ways to get a Kickstarter off? The darn thing is galled on there. Unsure

kijen
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kijen 8/8/2020 3:43pm
8/8/2020 3:43pm
Kickers is aluminum, shaft is steel. Pretty sure heat it up and the aluminum will expand a bit. Maybe a small gear puller?
Falcon
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Falcon 8/8/2020 3:49pm
8/8/2020 3:49pm
I'll try the heat. I don't have a gear or flywheel puller. It really should come right off but right now it's STUCK on there.
Paw Paw
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Paw Paw 8/8/2020 7:46pm
8/8/2020 7:46pm
Auto battery cable puller will get it off and is cheap.

Paw Paw
Falcon
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Falcon 8/10/2020 2:15pm
8/10/2020 2:15pm
Paw Paw wrote:
Auto battery cable puller will get it off and is cheap.

Paw Paw
Ah, there we go. Thanks, Paw Paw.

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