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I have an issue with my DT250E. Sometimes when shifting up into 3rd and/or 4th, I hear the "clack" that sounds like it went into gear, but it doesn't and when I roll on the throttle and let out the clutch of course the engine revs like it's between gears. I shift again and it goes right in. This happens maybe 20% of the time. I've tried holding the shifter up until I release the clutch but it doesn't seem to matter. No problem with 1st, 2nd, or 5th, or downshifting into any gear. I'm pretty well versed with everything mechanical except a bike transmission. If I split the cases what am I looking for? Any help is appreciated.
Not easy to diagnose that one without going in there as is an unusual problem.
I wonder if it's broken one of the pins No2 relating to 'that' gear but on second thoughts that doesn't pan out as you say two gears [two broken pins--i doubt it]. Had something similar in my very early 360 where the stop bolt was bent. Is an off set adjustable bolt in my case [RT2 360] but i'd arsed off on the concrete & bent [the bent or offset] screw from where it was set to give equal movement for up & down shifting.
So from that point of view check No8 in the second link. I'm surprised it shows a pin or dowel & not an 8mm threaded stop. If all looks ok then check the small spring & claw arm 21 & 20 in the first link. After all that & if all is ok then damn it you'll have ta go in & check the dogs & selector as same selector runs 4th & fifth on the main shaft. Actually i've cocked up as you say 3rd & 4th so that's two different selectors. 3rd is on the output shaft & 4th on the main shaft. Don't get confused by the diagram calling the gears in a different place. You want the sliding gears & the dogs on those gears & the dog slots they slide into [get round edged & kick back out rather than grabbing & holding but once fully in can be good enough to hold [till it gets worse]. Hope you can follow all that rambling--not sure i can lol. ps, Plunger & spring ok underneath
, can't see that playing up without doing so in all gears.
Before you go splitting the cases, Make sure parts 10-13 are installed and in good working order. If the spring is missing (common problem) it will miss gears and or pop out of gear. Had I caught this, I would have saved a full tranny rebuild!
Makotosun wrote: Before you go splitting the cases, Make sure parts 10-13 are installed and in good working order. If the spring is missing (common problem) it will miss gears and or pop out of gear. Had I caught this, I would have saved a full tranny rebuild!
I'm assuming those parts are accessible from outside the case? Maybe on the bottom?
It only took me 1.5 years to get around to look at this. What I found is that one of the previous owners had stuck the cam follower #10 into the bolt #13, then stuck the spring #11 into that. So the blunt end of the spring was acting as the cam follower, but had gotten bent and wedged up around the cam. Luckily the spring is still available, the cam follower is not, but it is still in good condition. Thanks for everyone's comments.
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