96 CR250 transmision problem

Foghorn Leghorn
Edited Date/Time 6/10/2015 7:32am
Hey guys, I picked up a clapped out 96 CR250 recently, and after riding it for about 5 minutes the transmission started acting up. The bike is locked in second gear. When the shifter is pushed down as far is it will go, the bike is in neutral, and when it is returned to the center position, the bike is in 2nd gear. Furthermore, when the shifter is lifted up, the bike will not switch to a higher gear, and seems to only lift about half as much as I would expect. The bike is disassembled right now, and the motor is pulled. I've got the clutch pulled out and can see the gearshift linkage and shift drum etc, but I'm not sure what I should be looking for.

Is the problem I'm describing sound like a problem with the gearshifter assembly, or is my problem likely in the transmission which is going to require me to split the cases and inspect gears and shift forks etc.? Any help is greatly appreciated.
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Paw Paw 271
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Paw Paw 271 5/31/2015 9:33am
5/31/2015 9:33am
http://www.bikebandit.com/oem-parts/1996-honda-cr250r/o/m11887#sch418250

This is a parts drawing of your shifter drum and etc. In most cases your problem will be with one of these parts.
#11,12,14,16,17 &18.
Broken or worn bushing, broke or missing springs in the dogs or return spring or broken or worn shifter detent arm and roller.
Also be sure that the center shift drum bolt is tight.

Paw Paw
RealityCheck
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RealityCheck 5/31/2015 9:36am
5/31/2015 9:36am Edited Date/Time 5/31/2015 9:39am
Paw Paw 271 wrote:
http://www.bikebandit.com/oem-parts/1996-honda-cr250r/o/m11887#sch418250 This is a parts drawing of your shifter drum and etc. In most cases your problem will be with one of these parts. #11,12,14,16,17 &18...
http://www.bikebandit.com/oem-parts/1996-honda-cr250r/o/m11887#sch418250

This is a parts drawing of your shifter drum and etc. In most cases your problem will be with one of these parts.
#11,12,14,16,17 &18.
Broken or worn bushing, broke or missing springs in the dogs or return spring or broken or worn shifter detent arm and roller.
Also be sure that the center shift drum bolt is tight.

Paw Paw
Beat me to it. It's very easy to install these parts incorrectly, which will result in the symptoms described by the OP. Plus, some of the little bits and pieces (the pawls, for example) wear over time. They're inexpensive, so it's worth inspecting/replacing them on a high hour engine.
Foghorn Leghorn 6/8/2015 6:59pm
6/8/2015 6:59pm
Okay guys, I took the shifting mechanism out and inspected everything and all the components seem to be okay. The ratchet pawls and springs etc all seem to work correctly in the shift drum. The shift drum itself is not allowing the gears to be changed. Does this sound like a problem with the shift forks meaning I am going to have to split the cases? If so, are case splitters specific to the bike or are they universal? Also will I need any other tools? Thanks

The Shop

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Paw Paw 271
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Paw Paw 271 6/9/2015 10:07am
6/9/2015 10:07am Edited Date/Time 6/9/2015 10:10am
Yes it's time to split the cases. Most case splitters will work if it's a name brand and adjustable. Look at Motion Pro or check e-bay.

Paw Paw
Foghorn Leghorn 6/9/2015 3:38pm
6/9/2015 3:38pm
Well the cases were split today and I found second gear to have a large chip out of it and the chip laying in the bottom of the cases. I'm thinking the chip must have been lodged in the shift drum which was not allowing it to shift properly. Anyways, $113 for a new gear. Wasn't expecting that haha
RyanLester761
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RyanLester761 6/10/2015 7:32am
6/10/2015 7:32am
Nice! Glad you figured it out. I read these forums for more knowledge (and to test my instincts, haha). I just picked up a new scenario and resolution. Smile

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