A forum for owners of Yamaha TTR250 trail and enduro bikes!

leigh · Senior Member

Bent the gear selector shaft

TTRfan · Super Guru

Bad luck!

Sorry but it's an engine out and crankcases split job to replace that shaft cry

Advice on posting photos here wink

Brian

leigh · Senior Member

Damn it. That sucks.

I'm fairly handy on the tools but that is going to be too much for me I suspect.

Bet it won't be cheap to pay someone to fix that

I am very tempted to try to bend it back. What do you think the chances of stuffing something internal or cracking a crankcase are?

It bent one way ok : )

Any ideas on technique to apply if I was to do such a thing. I'm thinking suitable hook and strap and my winch. With bike strapped to something immovable.

I guess the worse thing I could do would be crack the case.

Any advice appreciated before I get too curious and give it a go.

Cheers Leigh.

TTRfan · Super Guru

Hi Leigh

I doubt anyone wants to take the responsibility of damage by telling you to try and straighten it confuse

If I tried it you could bet your boots it would bend in the wrong place!

Brian

leigh · Senior Member

Understand. I'm not one to play the blame game though.

Quoted $1500 minimum for repair to split the cases. Likely to be closer to 2k or more as what's the point in fully splitting a motor and not putting new parts in. At least rings and valves etc.

I spent not much more than that for the whole bike.

Plan now is to bend the shaft. If I stuff it up well I'm still in the same situation.

Going to try to get some pipe over the top of it to bend it back. Not in the best spot for that, but see how we go.

Cheers Leigh.

leigh · Senior Member

Well sometimes in life you can get lucky and tonight was one of those.

Managed to bend it back to about 95 % of where it should be. Couldn't do the last bit of adjusting as the footpeg mount is in the way.

Need to get a mate to weld up a pipe attachment so I can bend in that direction. Seal has maybe a half a mm gap in the lower 1/4 of it. probably enough to weep oil, but it is the corner that it was stretched in when it bent. A whole world better than before.

I am going to buy a couple of seals tomorrow for it.

The markings on the seal were: A 27, 50, 14, 26, 6, HS

Can I get a these from a bearing shop, like the bearings seals for the wheels? It looks like a similar seal.

For anyone interested it bent back with not a lot of force. No way it was going to crack the case. I also bashed the lever back into shape. All in all a good night.

Cheers Leigh.

Cubber · Super Guru

Obviously the sun shines on the righteous biggrin

Congratulations

As far as the oil seal goes who knows? I don't - but knowing your luck it will be OK.

Martyn

TTRfan · Super Guru

He who dares.... Well done Leigh biggrin biggrin biggrin

The part number of the genuine Yamaha seal is 93102-14209 but I can't see a problem if you fit another manufacturer's seal as long as it is of decent quality. A double-lipped 14x26x6 seal is what you need!

Brian

leigh · Senior Member

Just an update on the repair. My friend had the idea to take my vice off the bench and use it to do the final straightening of the lever. One jaw behind the frame near the kickstand and one jaw on the shaft. Worked a treat. It looks completely straight to the eye, test rode and it is all fine works just as it always did.

Hard getting the seal out, ended up drilling a small hole with a 2mm drill bit and put a screw in it and pulled it out. I used a seal 1mm smaller (internal) than the original just in case it was off centre a whisker still. No leaks. Very happy with the result.

As usual thanks for all your help

Leigh.

mypobox · Veteran Member

Thats great news. Im glad to read you got it working.