2004 Crf250r. Just re-built the bike after it blew on me 5 years ago. Its the first time I have ever been into a dirtbike engine and i know i did everything correctly when it comes to the engine because the bike runs great and sounds great, i had a machine shop do the valves and my dad and i did the shims. I took my first ride on it today after the build, 1st and 2nd went just fine, couldnt get it into 3rd. When i shifted into 3rd, i let go of the clutch and the bike seems like its in 3rd, but once i hit the throttle, it acts like an engine break almost and kinda just slowed me down. I stopped for a second and sat there thinking, i rode again and gave it a little hell in 2nd gear, then it shifted into 3rd just fine. After that is when i found out that it wouldnt shift into 4th or 5th gear. Doing the same thing that it did with 3rd before i ripped it a little bit in 2nd gear. Tried ripping it a little bit in 3rd to see if i could do the same thing and get it to grab, but it didnt work. Everything sounds fine, no knocking in the engine or nothing, just not grabbing onto 4th or 5th gear. Prior to riding the bike today, i made sure that it shifted into all 5 gears, 1 down, nuetral, 4 up. That worked great when the bike was off, i just had to rock it back and forth to get it to grab all the gears as you usually would. Went for a test ride and then it did all of that. After the test ride, i shifted all the gears again with the bike off, just rocking it back and forth. I have no idea why it would shift when off, but with engine on and running it wouldnt grab the gears. Can someone please help me.
This may be a dumb question but I believe on that year of Honda they have separate oil for the engine and transmission.. so did you fill both the engine and the transmission? Each one is close to a quart if I remember correctly
They do in fact have seperate oil for the engine and transmission, i put lucas oil that had the density of the oil supposed to be in my crank part of the engine to break it in with because of the high amounts of zync. I put high density lucas oil in the tranny for break in oil because of the zync. my dad reccomended it because hes used it his whole life, could that oil not be getting in between the disks?
No that oil is probably fine, i guess I would verify for sure that it actually is going in to 4th and 5th gear with the engine off, and not just giving you some false click making you think you shifted up. (Could throw it on a center stand or something and turn it over in each gear [pull spark plug if need to make turn over easier] and watch to make sure the wheel is actually spinning faster and faster as you go through each gear. If it really is going through all the gears with the engine off im not too sure maybe clutch related? But if it’s not I would guess maybe one if the gears is on backwards? potentially two shift forks switched around? Forgot one of the washers on the end of the counter/main shaft? Tough to say because it would be pretty rare you could get a gear on backwards or switch the forks around and actually get the cases to go back together
I looked at a blowed up diagram of the whole engine and transmission to make sure that i had everything into the right spots. It could easily be a gear backwards but i did forget a few washers and realized after i got the case back together, had to split the case again and made sure that all of the gears were on the right way and the washer that i had left over went back into theyre correct positions. My dad and dads friend thought that it could be the clutch because the case was apart for about 2 years and it did dry out a good bit as in the clutch disks. I never got down to the shift drum or the forks of the shift drum only the top part of the tranny because when i was cleaning the case some of the gears fell off but like i said when i tore the case back apart i looked at that diagram to make sure that i put everything back together correctly. I will try putting it on a stan and spinning the rear wheel faster and faster tomorrow and see what it does then. Hopefully i dont have to split the case again I just want to be able to ride again yk. But if thats what i have to do then its what i have to do
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If you can verify it’s actually going into all the gears tomorrow you got me pretty convinced everything is correct inside. That leads me to next question what does it do when you try to shift up? The shifter doesn’t go up high enough to grab the gear or is it smoothly going up all the way but nothing happens? Could check your clutch basket for grooving, generally you’ll see that as more of an issue going into neutral but could be affecting what you got going on.. when you try to shift make sure you have the clutch lever completely to the bar and then wack the throttle once with the clutch still held in (this will get your steels and fibers to separate in you clutch basket) and then you can try to shift as its revving down with the clutch still fully pulled in
Alright i will test that tomorrow, ill reply and let you know what it is doing. If i can get it to shift doing that ill be amazed. I do beleive that it is going into 4th and 5th when the engine is off. I shift down from 5th into 4th and into 3rd all the way down. If it was just getting stuck in 3rd i would get to 1st quickly and it wouldnt let me go down anymore. I will make sure that it is shifting into all 5 tomorrow with the engine off just to be 100% sure. Its a weird thing going on and i couldnt find any youtube videos on it so its got to be rare for this to happen. I will try your clutch and throttle method tomorrow aswell and see what it does. I just dont get it. I got it to shift into third by giving it some throttle in 2nd which is just odd. Ill let you know, thank you for your help i appreciate it
And it feels like it is going up smoothly just not grabbing the gear and it feels like its going up all the way aswell but i could try to re-adjust the shifter and see if that does anything aswell. Maybe the shifter isnt going all the way up because i try to ease it into gear when driving it because of what its doing but when the engine is off i really try an shift it so ill do some tests and see what happens and ill lyk, again thank you
Sounds like you have the shift forks in the wrong groves not lined up properly in the shift drum. Always check it shifts properly before you put the cases together.
If it’s moving up all the way freely, and just not staying in gear you probably got somethin goin on with your “shift star” (idk proper term lol) it bolts on to the shift drum and there’s a spring loaded wheel that holds it at each location 1st, 2nd, etc I’d check and make sure nothing is going wrong there and that that part is operating smoothly at each gear. Could be a lot of things right there hopefully it will be obvious
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