85 250es big red won't shift ..pics

[bigreddad]

hey , just wanted to share some pics and ask a question ... Put red into reverse and then couldn't shift into neutral .. shift lever would not return up, but would return down if pulled up ... read thru service manual and started to dig into it .. the tip about jacking up motor to pull left side casing off helped alot...found broken gear shift arm ...looked up parts on bikebandit ..now for the questions ...i did not find all the pieces , i hope to find the remaining piece on the oil screen is this the next place to look ?? also , this broken piece , is it the weakest link so to speak , or do i have a bigger problem ??? shifting always seemed pretty normal although i am not the only rider .. thanks in advance for any imput .. and super thanks for this site .. that service manual is a complete life saver ..

[84honda200s]

wow that sux. but yea i would check the screen. if its not there then you may have some problems. as for prices i have no clue. i have a 200s lol

[Howdy]

If you have a pencil magnet you should be able to fish inside the case through a lower hole and find more pieces. They only cost $2-3 at a local Hardware or car parts store.
If you need a replacement arm for the Big Red let me know. I am sure I have one. Reasonably priced as well.
Howdy

[ATCwithdrawals]

I would guess that this was caused from trying to down shift back down to neutral while sitting still and with a heavy foot. very hard on those little arms when the bike is stopped and still in 5th gear and that is not the time to get it back to neautral.

[ste-pel]

I would guess that this was caused from trying to down shift back down to neutral while sitting still and with a heavy foot. very hard on those little arms when the bike is stopped and still in 5th gear and that is not the time to get it back to neautral.
thats how the one broke om my r

[bigreddad]

thanks everyone , i'll try that magnet and check the screen and , if bikebandit doesnt come thru , i will definately get in touch with you Howdy , thanks for the offer .. the lever broke on the downshift side of the spring but it broke at a standstill putting it into reverse .. good point .. thanks , i'll have to make sure i pass that along to my heavy shifting , heavy breaking , heavy beating on the red ...son of mine ..lol

[CorbinKale]

My '86 250ES engine began having shifting problems this evening. It will still shift up and down, but it takes a few tries, sometimes sticking in between gears like there is a neutral between gears. When the shift misses, there is a metallic 'clink' sound when the gear shift reaches its downward or upward limit. From reading the posts above, I am thinking I have the same problem, only it hasn't broken off completely, yet. I welcome any input before I tear into this thing. I am the only rider, and I don't stomp the shifter arm.

John, if you are reading this, it is the engine we installed at TF. I have put 1,000 miles on it since then, so it isn't any reflection on you! :lol:

[Dirtcrasher]

thanks everyone , i'll try that magnet and check the screen and , if bikebandit doesnt come thru , i will definately get in touch with you Howdy , thanks for the offer .. the lever broke on the downshift side of the spring but it broke at a standstill putting it into reverse .. good point .. thanks , i'll have to make sure i pass that along to my heavy shifting , heavy breaking , heavy beating on the red ...son of mine ..lol


Drain the oil, and go thru any holes you can with a magnet like Howdy says. And, under the right or clutch cover - there are 2 - 3/4" diameter holes into the lower portion of the tranny. One of those holes is behind a bunch of crap and unless you get every single broken piece out of there and finish your crime scene investigation, it's worth taking off an oil pump etc to access that other hole into the tranny.

Fill it with diesel fuel to let those pieces slosh around a bit and rock it around with the covers off and the drain plug out, then maybe you can get the shrapnel thru an access hole or the drain plug if they don't fall out. Engine oil can cause things to stick together and prevent your gravitational advantage :beer

It will come out, evry single piece will fit the puzzle or it's still in there.

[CorbinKale]

It will be a couple of days before I can dig into it. I found some other threads on this subject, so I feel fairly well prepared. Dirtcrasher posted some awesome info, in particular. I will remember the tipping on the right side technique, too. That thrust washer seems to be a common problem! Once I sus out the problem, I will pm you and we can work a deal. I need some fork boots, too, if you know a source. I need a more narrow front tire, but I will probably link up with Lomax for that. Once I have all that fixed, it will be just about perfect. I already have it rigged up to power my new Garmin GPSMap 60CSx in a handlebar mount. It is ideal for running around in the river bottoms.

No deer, but about 30 raccoons and 5 boar. Sulphur River bottoms is full of 'em! Yeah, about 1k miles since TF06. It is my daily rider for hunting, fencing, mowing and general running around the farm. Lomax calls it the camo-killer. :lol: