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Haha, right ok! Ok thanks

I made a longer key and refitted the wheel with retaining compound and thread lock on the screw. I'm reasonably confident it'll hold. I left it for a few hours and then tested it while the cover was still off. It now goes through all the gears so I'm happy with that! Do you know what torque the cover bolts should be? Thanks

I took a video of the movement before I removed it. https://youtu.be/T83MB9f0dYA?si=zNBbrbzu8d0kqVxk

Yes I've bought some 4mm key steel. Yes it is a bit worn as well. It really is very hard up but I'd rather not split the case if I can get away with it. I was thinking that a larger screw might have held in on there a bit better. Yes I'll use threadlocker on the screw and retaining compound on the shaft and keyway.

Thanks AnthonyT! Yes I'll let you know if it works!

Following on from this thread; I've finally got around to pulling the clutch cover off to have a look at the shifter ratchet mechanism. The screw holding the pinned star wheel has come loose and the wheel flops about. Unfortunately the keyway on the shifter cam has broken on both sides, I found both pieces. Anyone had this problem? The keyway on the cam "ramps" out, so I'm thinking of making a slightly longer key with a ramp ground into it. I'll put it back together with retaining compound. It may not work but I think it's worth a try.

Hi Mech, Thank you. I'll start a new thread with what I've found.

Thanks Mech. I will check it out some more and report back. The engine does run but with the combination of absolutely no brakes, the rear axle bearings being completely destroyed and not knowing the condition of the oil/filter, I didn't want to drive it too much to keep trying to shift it. I haven't got a service manual yet. Thanks for the info on the Babbits parts diagrams, they will be very useful.

Hi Mech, I rode a 1987 Kawasaki klf300 growing up. I assume the yamaha will shift similar? While rocking it, the first shift up from neutral most times doesn't find a gear, second shift does and then the next shift might find "neutral" (the light doesn't light). Thanks for the help.

Hello. I'm new to the forum, I live in the UK. I have just bought a 1995 Yamaha Moto 4 350. Generally the condition isn't too bad (I paid very little for it!), it looks quite original and all the plastics are quite good. The bad bits are no brakes, the rear axle bearings are shot and the transmission won't shift through the gears properly. I'm not planning on a full rebuild but I would like to sort it out a bit. The transmission is my main concern. If anyone has any ideas on what might be the cause I would be grateful. I can explain what's happening in more detail if required. Thanks everyone, Kester