Question about 2004 Yamaha YZ 450 F

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How to replace shift shaft

Not to sure i did a lil bit of research and look's like i start on the right side take off clutch ....then what?? do i have to take the motor out ???

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If you are going to dismantle a gearbox, Buy a manual. It is not something that can be accomplished without pictures (rebuild is even more critical.) They only cost about 20GBP and a professional gearbox rebuild will cost in the region of 400GBP- no contest is there.

Posted on Jul 22, 2013

Testimonial: "what s gbp? i have the manual i guess i take the clutch off then i can get @ the shifter shaft there's no video's on u tube how to can sum 1 kinda walk me through it or should i take my bike to sum 1 who knows how too.....i am pretty good at fixing my bike just no sure about taking off clutch sum 1 help... i can t afford to take it to shop so any thing any body can tell me will help thank'z guy's "

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Is it a big job to change your gear leaver spline. On a ktm 250 sxf


Its not to bad .You will need to purchase a shift shaft a shift shaft seal and a primary cover gasket and oil.First drain your oil.Remove your kick starter .Remove your primary cover.Remove entire clutch assembly.You will need air gun or a clutch holding tool to remove the clutch.Once you have the clutch assembly removed yuo can remove the shift shaft .Pay attention to the postion of the shift shaft in relation to the shift drum .Also pay attention to any shims on the shift shaft as that will need to be installed on the new one.Now remove the seal that the shaft was coming out of.Replace the seal install the new shift shaft.Make sure to center it in relation to the shift drum.clean every thing with brake cleaner.clean gasket area .Install the clutch assembly .If you have any trouble with the oriantation of the parts you can look at world of power sports for parts diagrams.Make sure you tighten the clutch hub to the proper torque spec.I would use blue loc tight on the nut as well .If you have a shop do it expect to pay about 2 hours labor max.Plus parts

Mar 11, 2015 | KTM Motorcycles

1 Answer

I have a ysr50 1987 and it will not shift past 2nd gear. I'm sure it's the shift lever but I'm open to any suggestions before I start taking it apart.


Hi, Anonymous and the usual suspects are:
1. Clutch not disengaging.
2. Bent shift shaft.
3. Shift fork bent or seized.
4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
9. Shift mechanism arm is broken.
10. Shift drum is broken.
For more information about your question and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
Need help with YZ80 shift problems
yamaha wont shift
YSR 50 Manual in PDF Format
OEM parts for Yamaha
http://mybikemanuals.com/yamaha

Apr 24, 2012 | Yamaha Motorcycles

1 Answer

Hello.Owner of 1990 XT600 2KF,30.000 km in very good condition. after een steep ride in first gear,I cannot shift to first gear.It seems stuck.Engine off: no problem changing gears. What can this be: Oil...


If the clutch is operating fine as well as the shift mechanism, it's either a bearing or a internally cracked case that's allowing the bearing to move. First gear is actuated on the rear transmission shaft that Is common to the drive sprocket on the left side of the bike, and an idler gear that engages the kick start lever to the clutch basket. This is located under the right engine case cover. Remove the chain and sprocket and check the shaft to see if it will move up and down in the bearing. If that's solid, remove the right side cover and check the case and bearing under the idler gear. I have had Yamaha cases crack at that bearing area and cause that same problem. Good luck!

Jun 13, 2011 | 1995 Yamaha XT 600 E

1 Answer

How do i change clutch release arm


I believe the arm is on top of the case on the left hand side attached to a shaft that goes into the case. It also may have a bolt in the side of the case below the arm that has a machined shoulder on it to retain the shaft from pulling out. If it does, remove it.If this is the way it's set up, it actuates the clutch thru a rod that goes all the way across the motor inside the hollow shaft that the clutch is mounted on. I don't have specific experience to the 250 KX, but I've been in the little ones and that's the way they're set up. So here's what you do-
Drain the gear oil and remove the round clutch cover on the right side of the bike. Remove the 5 or 6 washered bolts and the springs from the clutch pressure plate. Remove the pressure plate and you'll see the clutch lifter-it's a short rod with a flat bearing on it located in the middle of the clutch shaft. Remove it and using a small magnet tool go inside the hollow shaft and retrieve the actuating rod. There may be a ball bearing with it as well, although I don't think there is in that bike. Anyway, don't lose it if it has one and pay attention to which end of the shaft goes to the clutch arm. You can now replace the arm. When your putting it back together, rotate the arm with your fingers and make sure the lifter is moving up and down before you put the pressure plate and springs back in. Good luck!

Jun 13, 2011 | 2003 kawasaki KX 250

1 Answer

I have an 04 yz 125 that won't shift into 2nd but


2nd gear is at the bottom of the shafts if the tranny is stacked in the mag side case. So it is controlled by the bottom fork. You should be able to shift it thru all the gears by turning the shift drum. Make sure as you shift the shafts stay all the way in the output shaft and idler shaft bearings. As you shift it, look for full mesh between the wheels(shaft that goes to the clutch) and the gears across on the output shaft.
If that all looks good, the shifter cluster(on the end of the shift drum, with the 2 dogs that engage the notched wheel on the end of the drum) may not be lined up properly. If the gears and shift drum are new, I'm thinking I'd look there first. Good luck!

Jun 11, 2011 | 2004 Yamaha YZ 125

1 Answer

How do you change a shifter seal in a 07 ktm 250sxf


For a kwik fix you can take the shift lever off and use a dental pick and pull the seal out and replace with a new one, don't worry about messing up the one you are taking out but don't mess up the shaft. to do it right you have to remove the case on the clutch side and pull the shaft out from that side and them replace the seal.

May 07, 2011 | 2006 KTM 250 SX

1 Answer

I dropped my 82 CX 500 and snapped off the gear shift spindle - not just the shift lever but the shaft which the gear shift is attached. Any suggestions?


The shaft is pretty easy to replace. Just remove the right side casing and then the clutch and then the shaft is pretty much ready to pull out the right side. The shaft can sometimes get bent on a fall. cut the shaft nearly flush with the casing if it is bent. The bigger problem you will likely face is a bent shift fork or two. That would require pulling the engine and splitting the center case to replace the forks. Unfortunately the chances that a fork or two has'nt been bent are pretty slim. The bike will not shift properly with bent forks.

Nov 27, 2009 | 1983 Honda CX 500 B

2 Answers

I have a 2003 ford mustang gt stick shift. clutch sliping


sounds like you have a worn or misadjusted clutch, but if your clutch is self adjusting meaning a operated with hydraulic pressure (Brake Fluid) then you could have leaking slave cylinder that maybe wetting the clutch disc with brake fluid causing a slippage, or just a worn clutch, in which case you will need to inspect inside bellhousing...

Sep 11, 2009 | 2003 Ford Mustang

1 Answer

I HAVE A XZ3 YAMA VITORY ROYALE MOTORCYCLE AND THE BIKE WILL NOT GO INTO NUTRAL ITS STUCK IN 2 GEAR


You could have a bent shift fork. The engine will need to come out of the bike. Remove the top end, the flywheel and electrics, the clutch, shift shaft and kick starter and a few other parts. THEN you are ready to split the gearbox to get to the crankshaft, gears, shift drum and shift forks.
You will need an impact driver, flywheel puller, case splitter, torque wrench and factory service manual, plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer and say "Fix it". I normally tell people to take it to the shop just so they don't get into such an involved project and now they have a knowing eye working on the engine. About $800 to repair.

I would pull the right side cover and check the shift mechanism first. With the cover removed, you will see the clutch and behind the clutch is part of the shift shaft. Move the shift pedal up and down (as best you can) and you will see the arm behind the clutch move a bit. Is it hung up on anything on the end of the shift drum?

May 11, 2009 | 2003 Yamaha YZ 250

1 Answer

Broken shift shaft


  • Obviously a Kawasaki dealer can replace the broken shaft. I assume you want to replace it yourself. I do not recommend you replace it yourself but if you feel able then > > >
  • Drain the gearbox and pull the engine from the bike. Remove the left case cover.
  • Remove the right side case cover. Remove the clutch.
  • Disengage the shift shaft pawl from the shift drum pins and pin retainer. See if the bad shift shaft will slide out from the center casings. I say " IF " because the shaft may be bent and may not slide freely through the casings. DO NOT try to hammer the shaft through the casings. You will scar the bore at the least and crack or break the casing at the worst.
  • If the shaft will not slide out freely, then you will need to cut the shaft in half from the clutch side and remove it from the flywheel side. A Dremel tool will cut the shaft.
  • Now install the new shift shaft and check to be sure the gears all shift smoothly up an down, ( rotate the clutch shaft while shifting ). A bent shift fork is a PROBABILITY anytime a shift shaft is damaged as yours was.
  • If you can run through the gears okay then re-assemble the engine. Add fresh oil to the gearbox and go for a test ride down the street. If the bike does not shift smoothly then you missed a bent shift fork in the prior step and will need to tear the engine down, split the certer case and then replace the bent fork.
  • Please rate this solution as a " FixYa ". Thanks!

Mar 18, 2009 | 2003 kawasaki KX 125

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