First gear. Is no go

[newfiebullet]

Just finished building a Yamaha 225dx with a timberwolf swap and on the maiden voyage 1st gear won't engage..just kinda rolls and clicks...2nd to 5th work perfect...clutch is perfect and adjusted perfect shift smooth and easy....what might be the culprit?...this is the smoothest ,cleanest and quietest engine iv ever had and now this...arggg...bent fork? Can get a video tomorrow if it will help.

[barnett468]

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I would pull the cover and look at the shift fork and shift drum and try to shift it into first and see what happens . . also try to rotate the drum by hand to see if it goes into gear . . you need to kick it over while putting it in gear.
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[newfiebullet]

I'm gonna check the middle drive tomorrow..if its only first and reverse it may be in there..who knows..i m assuming I'll have to split the case the check/change a fork?

[barnett468]

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the prob is probably in the shift shaft and drum, not inside the case.

[newfiebullet]

Here's a video hope it helps
250 timberwolf first gear problem: https://youtu.be/hDucXFAzJ34

[newfiebullet]

Under clutch cover I'm guessing?

[newfiebullet]

Does anyone know if the shift shaft,forks,drum from a 200er would work? As ha a Dr 225 there as well if that's any good

[Yamaha3wheeler]

Do not split the case!! Make that your very last option and I still wouldn't recommend it. Been there screwed that up.

Another guy who is one of the kings of yamahas on here is Muthy. I'm sure he will chime in.

Anyway, to get into reverse you have to put it into first. You said neither reverse nor first works and it clicks in first.

So to me, when you put it into first it sounds like it is clicking in the housing the holds the reverse to 1st and 1st to reverse switch gears (middle drive gear assembly). Those gears allows the switch between 1st and reverse and reverse and 1st when it is in 1st gear only. Pull that cover off and look at the gears. It sounds like they are stripped badly or not aligning /meshing correctly. As mentioned, it is the gears that allow you to switch between reverse and 1st located in the housing circled in red below. If it works I'll take a Budweiser. Nothing fancy :)

Another note, that isn't even the correct housing. So you know it has been screwed with. The incorrect housing may cause the gears to not align/mesh properly.If the gears look good it may be an incorrect housing causing your problem. Get the correct housing. Here is a link on ebay. It is called a middle drive gear. Hell, it might even have incorrect middle gears. Look at the autozone clamp holding the yoke boot to the middle gear assembly. That gives you another hint. Anyway, You won't know until you take a look. Make sure that you know what year your engine is before swapping out middle gears.

These are what my 2 1985 225dr covers look like: http://www.ebay.com/itm/Yamaha-YTM225-YTM-225-DR-Tri-Moto-OEM-Output-Middle-Drive-Assemby-85-1985-1003-/131547451811?hash=item1ea0d6d1a3&vxp=mtr

I would investigate the above proceeding. I think if it was the shifter shaft it would do it in all gears. Goodluck.



See this picture:

http://i59.tinypic.com/2jan21g.jpg

[barnett468]

Here's a video hope it helps
250 timberwolf first gear problem: https://youtu.be/hDucXFAzJ34
I don't know about others but I doesn't help me because this is not what I asked you to do. .

[newfiebullet]

It's a 250 timberwolf motor is why the cover is different..I also blamed the middle drive but if the gears weren't meshing I wouldnt think she would run good from 2nd through 5th...I could be wrong...Barnett sorry it's not what you asked I don't have the engine pulled out yet...I asked about the other motors because I could check em out before I pull mine.haven't been in one of these motors other than middle drive which is why I asked if I had to remove clutch cover side.

[Yamaha3wheeler]

Ahhh, sorry. You did mention that it is a 250 timberwolf. I overlooked that. If it isn't the middle gears (which I would definitely still check) I don't know and sorry I couldn't be of help. For some reason I'm thinking when my lever was not locked into reverse or 1st correctly it clicked in 1st just like yours. Maybe the lever needs adjusting???? Maybe the back portion of the lever where it screws into the housing isn't correct (not in the correct position) and not aligning the middle gears properly?? did you adjust the reverse to 1st lever??? Move / adjust that lever and see what happens. This is where I would start and I'm almost and I said almost willing to bet that could be your issue. But for the record im not going to bet.

[Dirtcrasher]

More than likely an external shift locking mechanism.

Some of these guys have had 1000's of motors apart; I'm under a hundred.

Someone will respond and hook u up!! :)

[newfiebullet]

Hah thanks guys I used to tear in to honda s in highschool days but the yammys haven't given me a reason yet until now.I appreciate all and any help ...its gonna be Thursday before I can try any headway :(...I did adjust the reverse handle many times and I agree that that its nds like the culprit but I tried back and forth revse to 1st sharing it haulib on it to make sure I was locked in.

[newfiebullet]

Well I'm this far gonna pull the clutches soon check out other side on the shift shaft

[newfiebullet]

Grabbed a video of gear changes bit up rocking backa and forth but went through all 5 and back again

https://youtu.be/ivkY3PMakws

[newfiebullet]

Not having much luck with anything guess I'm splitting to base...anything I should know?..gonna order a gasket kit tonight

[newfiebullet]

Just thinking out loud here....I have a good 225 base here...from what I understand I can drop on the timberwolf head....and if I wanted get a 71 mm piston for a 225?I could do the head swap and ride away until I get a new piston.

[newfiebullet]

Split the case and everything looks good to me? Lol nice and clean and I can turn the drum by hand from one stop to the other...if nothing else now I can do all fresh gaskets and clean her out nice for some fresh oil....and the timberwolf sleeve dosent fit the 225 base so that's out.here's some pics of the gear218669218670218671218672

[barnett468]

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i would pull the shift forks and look on the sides to see if they are shiny or ground up.

[newfiebullet]

can do! im in this far so why not haha...ill report back with findings or hopefully none

[Yamaha3wheeler]

Man, I have to say that you did that quite fast. How tough was it to get apart? I would still check that middle drive gear. Mine did the Exact same thing yours did.

[newfiebullet]

2 hours I had this one to nothing and the 225 down to the base with the flywheel pulled...gonna put the 250 flywheel and stator in the 225 to match my current harness and run it like that until my gasket kit arrives...then I will start the 250 rebuild

[newfiebullet]

So better late then never...think I found the problem220304220305220306

[barnett468]

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yup, the shift fork is wasted but the gears still look useable for a trail bike . . would really need to see them in person though. . that being said, i would guess the sliding gear is a little gouged up in the shift fork slot, so i would definitely replace that one and it should be fine, but replacing them both is best.

[barnett468]

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if there is side play in any of the spinning gears, you can shim them on the opposite side of where the sliding gear engages them but dont remove any factory shims and place them on the opposite side of a gear.

check the shift drum slot for wear/damage.

[muthey]

Better late than never, That shift fork is definitely toast, and I would replace the fork and both gears as in the end they will wear a new fork quicker than if you replaced them. I have learned from experience that if you need to replace a worn part in a tranny replace all worn parts or you will be back in there soon. I credit that amount of wear to getting really stuck in the mud frequently and trying to rock it out.I myself wouldn't add any extra shims as yammis can get touchy about things like that. If you can get me measurements on the gears and the shift fork I will see if I have them sitting in my parts bin. From what I looked at a parts fiche the tranny from a 200 and 225 is the same as the timberwolf, so you can choose to use one of your parts bikes if you have one, or let me know and I have a complete one for sale at 50$ plus shipping

[newfiebullet]

I have a spare 200er there for parts..and the 225 in the bike.so no issue there..just finding the time is the problem. She is up and running in the mean time so no rush...little rough and odd lookin but fun as hell the drive.

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