Hey guys

I got a barn find 1977 dt 125 a year or go back and have just about finished restoring it to its former beauty.

Everything is looking great as you can see from the picture, engines running sweet.

The problem I’m having is with the gear box and I’m down to my second time splitting the case to try and see what’s going on.

All the gears seem in great condition with hardly any wear, slide freely and I can hold the gear drum and shift through all the gears easily.

The problem starts when I reassemble, it feels like the gear selector is jammed up and I can’t get anything.

I can literally stamp up and down on it and get nothing.

It’s driving me mad, any ideas will be well received.

Thanks

Shane

Driving 'me' mad too now, not being there or i'd gladly sort it for you. With the clutch cover off if you can revolve the selector drum & feel it through the gears then hook the claw arm on & try it with the gear lever. Not easy to give a sensible answer at this stage--well not from me anyway. Does sound like you're very familiar with the internals so best of luck going through it again. Partzilla is pretty good for an exploded view of things & they get their drawings right most of the time. This link is to a "78 but will be the same. Just wondering if the drum end bit with the pins, can be fitted on easily 'in the wrong possition' & looks like there's more than one option of ways it'll fit, but only one that's right. I'd guess there's an arrow or marking on 'that' part that has to line up with a marking on the center piece of the drum. www.partzilla.com/catalog/yamaha/motorcy...t125e/shift-cam-fork

I had similar problem with my 400. If the tranny is laid on its left side, counter shaft will fall to that side try lifting up on the main shaft while turning. This is where each shaft is pulled when tightened. Also if you install everything including up to the gear selector lever where your foot actually resides you can know for sure it is going to shift when assembled.

That’s correct devin,

Vin says 77 but I believe it’s a 78 2A6
I got no paperwork with it, just checked the engine and frame numbers, that are the same to make sure it wasn’t stolen before putting all the time and effort into restoring.
I’m in Australia too mate

I'm in NZ so we had the same models down here too.

Solved it, a piece had been broken off the selector arm.
See attached pic.
I can’t believe something so small could cause such a bloody headache!!!
I’ll have her running like a dream tomorrow.

Thanks guys

Congratulations!!!

(And thanks for posting what you found... I've never seen a detent arm break like that!)