SR250 - Problem Shifting Gears, Help Needed!

[benarmour]

Right, before i start, i'm a novice mechanic, so it might be really easy to solve this problem, so if that's the case, and it's just me being a bit stupid, i do apologise...
So, yeah, the problem is that i'm trying to fix this engine, and it's having problems shifting gear. The engine is fine about being in neutral and shifting into first, then going from first back to neutral, but it won't shift up past first. It feels like it wants to, but like there is something preventing it from doing so or something like that...
So if you've got any ideas about what the problem could be, and how i would sort it out, please help!!


P.S. before the bike found it's way into my possession (it was a total basketcase, and i'm attempting to achieve something with it) the bike had been sitting unused for quite a long while before it was given to me, which might help you in figuring out what is the problem here...

 

[jay_kent]

I'm having that exact same problem. Just found out though and haven't had a chance to figure it out.
Luckily for me I've got a working spare. If I can figure out how to unlock it I'll post back

 

[jay_kent]

Alright, I think I've found the solution to our problems. I've got a great motivator on this project (wife's bike), I don' know how you've got your engine, in the bike or on the table, but here's how I did mine. The engine is in the bike.

-Drain the oil
-Remove the right side footpeg.
-Take the bolt off the shifter lever but you don't have to remove it.
-Remove the clutch cover

The problem is how the shift shaft (#1) aligns with change lever (#14 next image)

Here's how mine looked. The arrow points to how the lever is miss-aligned, it's rotated one tooth counter clockwise of where it should be.

- with the shift shaft loose from the shifter. pull on the shifter till it comes loose from the lever.
- Change lever is spring loaded so once the shift shaft has been moved from change lever, with your finger push on the change lever until it aligns properly. Three teeth in four gooves.

As such.

Put everything back together. Fill with 1.3 litres of oil. 20w40 recommended.

Make sure you have all of the washers on the left side of the shifter shaft by the shift lever. It prevents the shaft from sliding off the change lever. I had to add another washer, was missing one but this engine was in a bike that was run over by a transport truck so if this was the only issue with my engine, I'm happy.

Went out for a 15 minute run and no problems.

Hope this helps

 

[benarmour]

Man, that is some brilliant help! Considering i'm a complete novice, i understood all of what you've said, and with those pictures i know what i've got to do now, thanks a bunch! I think that will definitely be the problem, when i got the bike, the shaft was loose, so when i put it back on the rod, i must've just mis-aligned it
I'm not touching the bike for a couple of weeks, it's locked up in the garage until i finish my exams : I'll report back though once i've tried your solution, thanks again jay!

 

[jay_kent]

glad to help