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RD400 shift fork orientation?

Started by JBeasty, August 17, 2022, 08:57:42 PM

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JBeasty

So I put my shift forks in following the parts catalog (and Dusty's RD400e engine build), and the Factory Service manual. Now that I look closer, the shift forks marked #2 are on the right side (clutch side) and the shift forks marked #1 are on the generator side - on the parts catalog and in Rusty's thread. But the manual has them the reversed. Whats the consensus of those that know all things RD? (The photo's are of my case).
Thanks, JB
1977 RD400

JBeasty

#1
Here's a pic from the manual
1977 RD400

JBeasty

and this is from the Parts catalog
1977 RD400

Aloha808

So I currently have two rd400 engines split open on my kitchen table.  I am using one of them as a model to help put together the one being rebuilt.

Anyway, the shift fork orientation that I see is like the parts catalog picture.  A better pic (from above) of your engine would help.

Hopefully someone with way more experience then me will chime in. 

JBeasty

#4
Correct, I have mine set up like the parts catalog. The numbers I'm referring to are the raised ones on the forks (there's 2ea #2, and 2 ea #1). Pay no attention to the black marker ones I put on there to help me remember how it came apart. I didn't take a pic of them when they were still in the case, so they're useless  :bang:

2 engines all apart on the kitchen table! That's...  dedication!!  :olaf: :shocked:  :Clown:
1977 RD400

1976RD400C

Hmm... the service manual seems to be wrong. The number 2 forks are on the clutch side. 

shiftfork" border="0
shiftfork2" border="0
'76 RD400 green  '76 RD400 red   '84 RZ350

1976RD400C

What manual did that pic come from? Here's the pic in a Yamaha manual.

shiftfork3" border="0
'76 RD400 green  '76 RD400 red   '84 RZ350

JBeasty

It's supposedly a reproduction of the original? Maybe I need to look for a different one.
Anyway, thanks everybody. Looks like I have it set up right.
1977 RD400

SoCal250

The photo in reply #1 is the same as my factory RD400 manual (with the copper colored cover), on page 43. (Yamaha part # LIT-11616-RD-40)
75 Yamaha RD125B   75 Yamaha RD125B (project)
75 Yamaha RD250B   75 Yamaha RD200B (project)
73 Yamaha RD350     77 Yamaha RD400D   79 Yamaha RD400F  
91 Yamaha TZR250R  89 Yamaha FZR400   05 Yamaha FZ6   
05 Yamaha XT225TC  82 Honda MB5  02 Aprilia RS250 Cup (sold)

JBeasty

Well shit. That's the same as my manual, (page 43 from the LIT-11616-RD-40 manual). Which way is correct then? Anybody have their engine together and shifting correctly, that can confirm which way they put in the shift forks?
1977 RD400

1976RD400C

The number 2 forks go towards the clutch. 1 and 2 are different sizes, the diameter of the channel they fit in on the gear is different sizes. The gear shafts will not drop in all the way if they are mixed up. I found that out once with the same question about what goes where.
'76 RD400 green  '76 RD400 red   '84 RZ350

rodneya

Quote from: 1976RD400C on August 18, 2022, 04:52:40 PM
The number 2 forks go towards the clutch. 1 and 2 are different sizes, the diameter of the channel they fit in on the gear is different sizes. The gear shafts will not drop in all the way if they are mixed up. I found that out once with the same question about what goes where.

Thats good to know. Putting everything back together according to your manual, only to find you have to rip it all apart again is a sure fire way to ruin your day.

JBeasty

That IS good to know. I'll leave it the way it is, and report back if there's an issue. Makes me wonder how many people come across this problem, with conflicting manuals.
1977 RD400

SoCal250

Added this info to the Tech Library :thumbs:
75 Yamaha RD125B   75 Yamaha RD125B (project)
75 Yamaha RD250B   75 Yamaha RD200B (project)
73 Yamaha RD350     77 Yamaha RD400D   79 Yamaha RD400F  
91 Yamaha TZR250R  89 Yamaha FZR400   05 Yamaha FZ6   
05 Yamaha XT225TC  82 Honda MB5  02 Aprilia RS250 Cup (sold)