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Old 11-15-2012, 03:06 PM   #1 (permalink)
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Driveshaft doesn't clear!

I have a 1981 yamaha srv 540 and am changing the track. Everything was going well until I tried to take the driveshaft out. I took the chaincase, speedo bracket, and bearings out. When I try to slide the driveshaft toward the chaincase side, the driveshaft doesn't come out of the other side. It needs to move toward the chaincase side about another 1/2 of an inch. I don't know what to do to get it out. Any advice would be appreciated.
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Old 11-15-2012, 03:09 PM   #2 (permalink)
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Move it to the other side. Most have to be pushed towards clutches and than come out of chain case wide first


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Old 11-15-2012, 04:47 PM   #3 (permalink)
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No, if I push it to the other side toward the clutches, it needs like 2 inches more to come out of the chaincase side first. The driveshaft has 4 drivers that are held in place by collars that have set screws to hold them in place on the shaft.... Do I need to remove these to get the shaft out? I tried removing them already but they are pretty badly rusted and don't budge. I may try to heat them up and pound on them to see if that will break them loose.
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Old 11-15-2012, 05:33 PM   #4 (permalink)
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It will come out. I had one. It was a bear.
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Old 11-15-2012, 05:36 PM   #5 (permalink)
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Driveshafts are a PITA to get out. You've gotta tilt it every which way till you find the right way to get it out. There's no easier way to get them out, unfortunately.
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Old 11-15-2012, 05:44 PM   #6 (permalink)
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You do have Both bearings off? You may have to remove or atleast loosen the chain case?
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Old 11-15-2012, 06:14 PM   #7 (permalink)
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Yes, I have both the bearings out, I was wonderin gif I have to remove the collars that hold the cogs/wheels inplace on the driveshaft and push them so I can move the driveshaft farther to one side?
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Old 11-15-2012, 06:38 PM   #8 (permalink)
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NO don't remove the drives! Remove the chain case instead!
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Old 11-15-2012, 07:02 PM   #9 (permalink)
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on that sled you have to loosen the two outer wheels. they are only guide wheels, not drivers, you dont really even need them on there but go ahead and keep them. be sure and mark the location although the markings on the shaft should be evident. no way to get the shaft out otherwise.

heres the butt kicker. those little set screws will be stuck. they strip easy as well. being they are like a 2.5 or 3mm allen head, if you have cheap allen wrenches you can twist them up almost as easy as stripping the set screws.

in other words, use good tools, be sure and pre-soak with kroil or pb blast, and if your up to it and careful, some stragetically place heat will help.
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Old 11-16-2012, 07:19 AM   #10 (permalink)
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Thank you yamadad4. That's what I figured I would have to do. I have already tried getting those set screws out and as you said, they were stuck. I have been hitting them with pb blast and am letting it soak. I will continue to try to get them out. Thank you for the help!
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