Well guys, I give up.

[fulltiltrider]

Well I finally got done with my r, or so I thought. Pulled it out of the garage started up, Put it in first, pulled out shifted to second. When I left off the shifter it just went back into nuetral. Shifted to third, same result. As long as I keep pressure on the shifter it stays in gear. If I let my foot of the shifter it goes into neutral in any gear. Im assuming I messed something up with the drum or something. Regardless I probably have to split the cases again and I just dont have the time. Looks like Ill be taking it to the shop and get raped and hope it will be done by quad fest. Anyone ever hear of an issue like that? There is no grinding or anything like that, Im stumped

[quadracer87]

im sorry to here that bro. that really sucks. i hope you get that beast right.

[flotek]

didnt you bench test before you put it back togehter ?

[Paulie B]

I feel your pain. That's why every start after a re-build has me holding my breath!
On my motor I learned the hard way not to even touch the shifter with the clutch cover off. If I do the mecanism jumps some teeth and I end up with only 1st or no gears at all. After removing the clutch basket and setting it straight I figured out the clutch cover is what holds the shift shaft gears meshed.

[FPMXer]

Dude, don't take it to the shop. Do like PB mentioned and fix it yourself. Drain the oil, remove right side engine cover, and look at the fork while you have someone else shift the bike and see what it's doing. If you can't see the fork on the shift star then remove the clutch basket and make sure all the springs are installed. It sounds like you missed a spring or it's installed incorrectly.

[flotek]

the return spring

[fulltiltrider]

Denny I think it might be the return spring or something simple. I did turn everything after I first put the cases together and all seemed fine. Now Ive started it again and rode it slowly down the alley. Now its going into all the gears fine while shifting thru them, no more nuetral between every gear . Its just a little notchy trying to get it back into first. Again, no grinding or binding. The tranny seems to be meshing fine now, just doesnt downshift real smooth. Maybe I just need to ride it around a bit To let things settle lol.

[fulltiltrider]

Originally Posted by FPMXer

Dude, don't take it to the shop. Do like PB mentioned and fix it yourself. Drain the oil, remove right side engine cover, and look at the fork while you have someone else shift the bike and see what it's doing. If you can't see the fork on the shift star then remove the clutch basket and make sure all the springs are installed. It sounds like you missed a spring or it's installed incorrectly.

Well its not a money issue. Its a time issue. As most of you know I travel all over the east coast for my job. I really want to do it myself but, if there is a major problem, quadfest is only a month away. Which would leave me one or two days to work on it between now and then.

A 250r tranny is very simple. No springs except for the pawl. I didnt take the gears off the shafts or anything as it ran fine when I tore it down. Shift forks and the drum is all I can think of in the cases that might be a problem.

[Paulie B]

Damn glad to hear the good news Jim

[fulltiltrider]

Well not good yet. I just tried it again and it went into nuetral between 4th and 5th., and the shifter is real notchy. Im gonna have it tore down.