shifting problems, bike falling apart

**monster 84r** · 07-23-2005, 05:53 PM

i just talked to someone at a dealership who told me i would have to take out the whole motor, remove the cylendar and piston, and split the cases to get to the messed up fork. is that the case? who in the az area works on bikes like this for cheap? any help appreciated.

**gasmask** · 07-23-2005, 06:14 PM

about 3 weeks ago me and a friend was playing around with out bikes. he has a banshee and i am still building an atc 500...i reved it to high before shifting so it wouldn't go into 2nd gear...after letting it sit for 3 day i change changed to a 50/50 gas mixture...went to ride it and going to 2nd gear it reved up,locked the rear tires and shut off...trying to shift to 1st or netural was impossible without jumpping off the bike and rocking it back and forth like a mad man for 5 minutes...this happened 4 times after cranking it, shifting it and rocking it...now if i skipped 2nd gear it worked fine...so i went and split the cases and found that one shift fork was rubbing against 2 gears...so the gears and the shift fork needed to be replaced...now it shifts....

**resto250r** · 07-23-2005, 06:24 PM

Hey Monster I have an 83r which is the same exact bike anyways I've been in my bottom end before I do know that the shift spindle itself cracks in between teeth from standing on the shifter to go into 1st, I clamped it back together and welded it since they are hard to find. I do see them on ebay and have been tempted to buy one 4 a spare. You will have to pull the motor off the frame to get the cover off though sorry. Where r * @ in Az I'm in glendale?

**monster 84r** · 07-23-2005, 06:24 PM

what exactly is involved in splitting the cases? how much would this cost to have some one do it 4 me?

**monster 84r** · 07-23-2005, 06:26 PM

o im located in mesa, lyndsay and mkcellips. do * know of anyone who can do this for me resto? i cant take it in.

**speed20** · 07-23-2005, 07:41 PM

Hey Monster......I had a 200x that had a shifting problem....wouldnt shift into 2nd, but all other gears worked fine....split the cases, turned out to be the shift fork rode (rod that holds the shifting forks in place) was bent....couldnt tell by looking at it, but you put it in a drill press and it would go side to side like crazy. I live in Ohio, but have had experience with quite a few 4 wheelers, 3 wheelers, dirt bikes and street bikes (worked at a cycle shop for about 3 years).....if noone else wants to do the motor work, i would be glad to help a fellow triker! if your interested, PM me and we can work something out.

**monster 84r** · 07-23-2005, 08:01 PM

thanks man, ill let you know if i cant find out whats goin on, and find out a way to get her up there. i just called the previous owner back, and it turns out that he moved 1st gear two clicks away from second, thus making me have to double shift. he said he did this so that his girlfriend could ride it and have more control of the gears

. i called the dealership and they said that if this was done , it could keep the fork from hitting 5th. he had some weird name for what i had to adjust. some part that catches on the drum of the clutch. he said i could fix it but taking off the clutch cover and going from there. anyone know how i should fix this? even if i cant get to 5th afterward, at least i dont have to double shift to get to 2nd gear.

**speed20** · 07-23-2005, 08:14 PM

I have never heard of anyone moving gears to different positions......sounds to me like he is

. Im not even sure if it is possible to be honest with you, unless it is a totally different transmission.

**monster 84r** · 07-23-2005, 08:39 PM

he must have been an idiot to do that, but from what the techy told me its possible.

**bigredhead** · 07-23-2005, 09:15 PM

Are you sure you were able to go to 5th before ?

I have a thought but it would mean never beeing able to reach 5th in the first place....

**monster 84r** · 07-24-2005, 01:52 AM

no i was never able to go to 5th gear. since i bought it. how can i make neutral 1/2 between 1st and second?

**monster 84r** · 07-24-2005, 02:33 AM

bigredhead, ** theory is probly right because ive never been able to get to 5th. the guy i talked to said this arm that clicks onto the outside of the clutch drum has been messed with.

**resto250r** · 07-24-2005, 11:26 AM

I would tell * 2 bring it by but your in mesa I'm in Glendale.

**DIGGER DOG** · 07-24-2005, 02:17 PM

Hi Ya , I know this is about 11 hours since the last posting so i dont know if you are still monitoring the post or not?
I am by far not an expert and im not a know it all but i am attending MMI (Motorcycle Mechanics Institute) Like I say im definately not an expert but my diagnosis would be a bent,or broken shift fork and or fork rod and or damage to the shift drum probably leading to damage to the gear or gears themselves since you have shavings in the oil,.
Definately get a manual,and some decent tools , ive torn down about 3 trannys so far at school a 350x, xr 200, and a Harley davidson. on an air cooled R it shouldent really be a big deal but yes you do have to remove the head ,cylinder ,and split the case, just get all your gaskets and such before hand ,it would be a good idea to research for shift forks,fork rod, etc.. to see if they are still available from a dealer or get a parts motor, It may really seem like a big task but even when I tore the 350x down ( and had to do it about 4 times the top end any ways bottom once) it really wasent bad and the 350x has considerably more parts than an air cooled R its really not a chore if you have the tools I think you may need a rotor puller?? not too familiar with the Rs but i would imagine youd need one the clymer or haines manual will go into more detail than the honda manual but i prefer the honda manual . but i would suggest getting clymer because it should walk you through it step by step just take your time and get the tools you need .
But if you are too intimidated by it ( I was definately intimidated doing transmissions before i actually did it ) then definately find a decent mech. that will do it and maybe ask if you can help do it too maybe you could get it done cheaper too but I think you can do it though especially with all the help from this site and other members espcially the 250R guys here.

**monster 84r** · 07-24-2005, 02:35 PM

that sounds like the culprit, the shift fork, but im trying to knock out all the possibilities before i split the cases. does anyone know how messing with the 1st-neutral-2nd gear pattern could put 5th gear out of whack?

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