November 22, 201114 yr I have a Yamaha engine which has had the gearchange shaft sawn through and the splines removed. All I have left is a round bar of approx 25mm in length. The challenge is to make it useable without splitting the engine. Any ideas from all you bodgers out there????
November 22, 201114 yr If you have 25mm (1 inch) sticking out then you could try grinding a flat on one side of the shaft and make a gear lever with a cotter pin, i.e. same as a BSA kick start.
November 22, 201114 yr What Yamaha engine is it? If its a ty175 then its easy to just replace the shaft by removing the small cover.
November 22, 201114 yr Do you still have the dawn off end and what is the diameter of the shaft? I would suggest drilling, tapping and threading the shaft so you can bolt it together with a 12.9 minimum grade socket cap screw (Allen key bolt). Then using hardened dowel pins to locate and lock both parts together. The diameter of the shaft will determine what diameter bolt and dowel pins to get, for instance if the shaft is 15mm diameter you could use an m6 bolt and 2 x 2mm dowel pins. Hardened dowel pins can be had here: http://www.boneham.co.uk/ShowProducts.aspx?CategoryID=5
November 22, 201114 yr Almost all yamahas can have the shift shaft replaced without splitting the engine. Most are just under the clutch cover.
November 23, 201114 yr Author This is the TY250 twinshock which is a full engine split and I'm too lazy to do. Thanks for the help it has sparked off some ideas which I was hoping it would.
November 23, 201114 yr TY250 twinshock gear change shaft replacement does not require the cases split, but does require removing the clutch cover and the clutch basket. There is a circlip on the LH end of the shift shaft and once it is removed, the shaft slides out towards the right. Replacing the shaft is probably less work than repairing the cut-off shaft.
November 23, 201114 yr This is the TY250 twinshock which is a full engine split and I'm too lazy to do. Thanks for the help it has sparked off some ideas which I was hoping it would. Remind me never tto buy a bike off you !!
November 23, 201114 yr Author No worries you look more into heavy metal than me!!!! However the clutch basket off looks within my attention span, now just got to find a good shaft ho hum
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