Hi all
         I have rebuilt my 1980 XT 250 but although it will shift down into first gear i cannot get it up into second it just stops . New clutch plates , cable,  adjusters etc & i followed the manual for re assembly but it will only shift down one place also getting it back up into neutral is tricky but then it aint going any further. Any help appreciated

Most likely cause is that you have installed the shift linkage sector gears "out of time". 

There are normally "timing marks" on the linkage gears that need to be lined up.  Shift shaft (1) at the link below has one half of the sector gear shown on the left end of the drawing.  Those teeth engage another plate that makes the linkage that rotates the shift drum move.

www.partzilla.com/catalog/yamaha/motorcy...0/xt250g/shift-shaft

 

Many thanks Mark , looks like the side casing is coming off again !!!!

Many thanks MarkT it was the Pawl misaligned seems to be changing gear ok ,need a test run but i am confident that issue is fixed.

Also be careful if the return spring has been off the change shaft as spring ears have to be parallel  not crossed which is their natural state until fitted. That isnt relative in your case though but can be a trap & end up with a loose lever free play up & down when resting in the central position.

Many thanks i will keep that in mind