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Discussion Starter · #1 ·
I took my stator cover off to replace gasket, cleaned out stator area, reinstalled cover, and now the shifter wont shift? I've been trying all night to try and resync` the gears to get shifter to work, with no results. Anyone have any good advice on how to resync the gears to get shifter to work?
 

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if it was shifting fine before you took off the stator cover then you will have to pull the cover back off and check out your shift linkage that turns the star type ring for the shifting drum. something is out of place. get the bike off the ground when you do it so that you can turn the rear wheels and check and make sure it is shifting fine before you put the cover back on. you can also manually turn the shift drum with the cover off.
 

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Discussion Starter · #3 ·
250x transm

I had the stator cover off, removed the ratchet mechanism, turned shift drum clockwise to go from 1st through 5th gears , and all the way back down to neutral, I would reinstall/remove ratchet mech. between shifting gears and turning rear wheels. Still no luck. The next thing I'm gonna try is fill oil back into engine, and start her up, put her on ground and run in reverse back to neutral, and see if things magically work again. I literally touched nothing on gear shifter or reverse lever while removing cover, or reinstalling cover, or even cleaning out stator side of engine.
 

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i had the same probblem.finally i just gave up and took it to a friend that works at the local dealer
 

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Discussion Starter · #5 ·
250x transm

Yeah, I had this problem once before, but I forgot how I resolved it. I'm trying not to pull the engine and split the case.
 

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Yeah, I had this problem once before, but I forgot how I resolved it. I'm trying not to pull the engine and split the case.
There's no reason you should have to split the case. If it was working when you took it apart, then you just have something out of place.

Here is a diagram. This is for a 300EX, but the shifting mechanism should be the same. Maybe this will help. Be careful not to lose that little small bushing behind that plate, all the way to the right of the diagram.

 

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Discussion Starter · #7 ·
250x transm

Thanks Helmut. Yes the 300ex is the same as 250x, the shifter drum works fine, it's the shift pedal, that is not moving up or down even with the clutch handle pulled in. I went through all the gears fine moving the shifter drum mechanism, but when I tried the shift pedal during the shifter drum changes, the pedal won't move.
 

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Did you notice if the lever that goes to the shift drum got nocked out of place? can you take a couple of pics of the internals and post? clear close ups!
 

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Discussion Starter · #9 ·
250x transm

Yes 69quadracer, I did checkall parts. The only thing you can't see is on the other end of the foot shifter shaft, is like three fingers in which actuate the shifter drum I believe. Thats what I can't see.
 

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That can be really tricky if you run into any trouble let me know i had my motor tore down that far not to long ago to change the crank and the shift drum fell out. Its a bitch to get it to go back in right.
 

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Oh and another thing how long did you have it without oil in it? Because your clutch could be stuck and not disengaging to let you shift. Also you could be way out of wack with the shift drum if you turned it through the gears without rocking it back and fourth to actually making it go into gear. You have to be moving to go into higher gears. When my shift drum got stuck i had to push it forward ever time i shifted the drum into a different gear. If i didnt it just locked up. Hope you havent got the thing all tore apart yet because i kinda doubt your shift drum just happened to go bad while your were working on something completely different.
 

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Hope you havent got the thing all tore apart yet because i kinda doubt your shift drum just happened to go bad while your were working on something completely different.
Yeah, I was thinking the same thing.
 

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I bet he just turned it without letting it go in to gear. Mine locked up everytime i did that. Then i would roll it forward and it would go into what ever gear i was in before and be way out of wack. Syncing the gears is no sort of fun.
 

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Discussion Starter · #15 ·
250x transm

I tore it down on Saturday, then got called into work for a couple hours, so when I got back to it I tried to rush it back together, but it's not worth rushing so I bagged putting it back together until I have good time for it. Went ridding Sunday with a buddy's Suzuki 250 quadsport, and had a blast!!!!!! I will get back to slowly reassembling on Tuesday afternoon. Yes I did rotate the sprocket during gear changes. What I don't know is will the gear foot shifter-shift when you don't have the clutch engaged- I think I went to far and made a mistake. Sounds like I may have answered my own question-That's the learning curve lol
 

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As long as the engine isn't running, you don't need to use the clutch to shift gears, but you will need to turn the flywheel or output shaft so the gears will turn and mesh properly to engage.
 

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The only thing that will make it not shift up or down is if you have the piece that goes on the end of the drum on wrong. It will have a spot that it will only go one way and fit all the way down on. Like helmut said you dont need to engage the clutch unless your moving. But if you get this piece on back words it will not shift up or down. You need to make sure that you line the mark in the shift drum with the ratchet wheel. That shifts it into NEUTRAL. But make absolutely sure you put some locktite on the bolt that goes down the center of the shift drum. I had to experiment with this one on an old motor from a 300ex i had sitting around. I put the piece on backwards and it wouldnt shift up or down.
 

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Discussion Starter · #18 ·
250x transm

I did put the drum in the correct way, it can only go in one way, to fit properly. I did put the ratchet shifter housing in so the indent on the back of it lines up with the shifter drum. Then I put on the ratchet mechanism, which can only go on one way to line up with the reverse shifter bracket. Yes I thread locked the bolt in center of ratchet housing. Even if I try to manually shift, the foot shifter won't move. I will try again when I get home today. Thanks guys for bearing in there.
 

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Well man i am stumped then. You did get it to move when you took the cover off but when you put the cover back on it wont move up or down? Or did i read this wrong?
 

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Discussion Starter · #20 ·
250x transm

The quad was in running and shifting condition, beforew I removed the stator cover. Then I removed the stator cover to replace a leaky gasket. Put new gasket on reinstalled stator cover, and walla, I noticed that I could not move the foot shifter. So should you be able to move the foot shifter through all gears with the clutch when not running, or do you have to have the engine running to allow the foot shifter to work properly? I did get the engine back together, but have not installed the right and left covers yet.
 
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