Hawk 250 Nuetral & Transmission Problem - Page 3

Megadan · 10-03-2017, 02:47 PM

Quote:

Originally Posted by Ariel Red Hunter

I think CSC has them. There are guys on here that can post a link to CSC,

Speak of the devil and he shall appear...

http://www.cscmotorcycles.com/TT250-...p/zt18-100.htm

Ariel Red Hunter · 10-03-2017, 04:04 PM

Quote:

Originally Posted by Megadan

Speak of the devil and he shall appear...

http://www.cscmotorcycles.com/TT250-...p/zt18-100.htm

Megadan, thanks for posting the link.

Andizzle · 10-03-2017, 09:19 PM

Do you think it's worth a shot to try and bend out?

Merlin · 10-03-2017, 10:04 PM

Quote:

Originally Posted by Andizzle

Do you think it's worth a shot to try and bend out?

Yes for sure.

Andizzle · 10-03-2017, 10:24 PM

I moved the shift lever down a notch and left off the belt cover so it would be free'd up. i tried sitting on the bike and bumping it back and forth to see if it would shift past 2nd. It didn't. So I decided to take it down the block to see if maybe running it would once I got 4 houses down this happened.

Ariel Red Hunter · 10-03-2017, 10:25 PM

Quote:

Originally Posted by Andizzle

Do you think it's worth a shot to try and bend out?

In a word....yes. That little test proves nothing. The gears don't normally shift more than 1 or 2 gears with the bike sitting still. You won't know if the internal parts are de-ranged until you try to shift it while it is moving. So correct the bend, put the shift pedal back on and see what happens when you ride it.....ARH

Andizzle · 10-03-2017, 10:28 PM

I'm guessing the shifter pawls ended up falling off the studs, and now it's stuck in neutral because it fell off. Does that sound right?

Andizzle · 10-04-2017, 01:15 AM

Jerryhawk250 sent me a service manual with the same engine, and in the transmission troubleshooting area, I found a page that gives me some ideas to what could be messed up with it.
TROUBLESHOOTING
Hard to shift
• Incorrect clutch adjustment
• Damaged shift drum cam groove
• Bent shift fork
• Bent shift fork shaft
Transmission jumps out of gear
• Worn gear engagement dogs or slots
• Damaged or bent shift fork
• Bent shift fork shaft
• Damaged shift drum stopper arm
• Broken shift linkage return spring
• Damaged shift drum grooves
Excessive noise
• Worn connecting rod big end bearing
• Bent connecting rod
• Worn crankshaft main journal bearing

**JerryHawk250** · 10-04-2017, 08:18 AM

I'm assuming you bent the shift lever so it doesn't hit the case any more allowing you to upshift completely and not hit anything. if so then you definitely have something not meshing up in the transmission. I would pull the right side cover off and inspect the camplate and selector plate area since that would be the easiest to get to and probably one of the first things to be damaged. Did you adjust the clutch yet? On these bikes you can't have too much play in the clutch are you will have trouble shifting.

Andizzle · 10-04-2017, 09:13 AM

Yes I adjusted the clutch and it wasn't pulling anymore. As soon as I tried to ride it without it hitting anything then that's when it slipped out of gear completely. I'll go ahead and pull the cover off then. Is it the right side of the bike if you're sitting on it?

**JerryHawk250** · 10-04-2017, 09:19 AM

Quote:

Originally Posted by Andizzle

Yes I adjusted the clutch and it wasn't pulling anymore. As soon as I tried to ride it without it hitting anything then that's when it slipped out of gear completely. I'll go ahead and pull the cover off then. Is it the right side of the bike if you're sitting on it?

Yes, the right side when sitting on the bike. Hope the manual helps you out.

Ariel Red Hunter · 10-04-2017, 11:11 AM

Quote:

Originally Posted by JerryHawk250

Yes, the right side when sitting on the bike. Hope the manual helps you out.

When you have all of the bolts out, tap the case around its outside with a rubber or plastic hammer. Gently. If you don't have a rubber/plastic hammer, use a piece of 2X4 a foot or so long. That way you won't have to replace the seal....ARH

Andizzle · 10-04-2017, 10:33 PM

I'm gonna try to take it off tomorrow it's been raining most of the day here. I already got the rear brake pedal off so I can get to the cover bolts easier. And I took of the clutch cable at the bottom. After that, I'm going to need to drain the oil and then take the cover off, right?

Mudflap · 10-05-2017, 07:30 AM

You can drain the oil or lean the bike way over to the right so the oil will go to the other side of the engine.

Andizzle · 10-05-2017, 08:58 PM

Ok so I got the cover off I'm not exactly sure what I'm supposed to be looking for so I just took a video of the inside of it to give you an idea.

10-03-2017, 09:19 PM	#33
Andizzle Join Date: Sep 2017 Location: Lubbock Texas Posts: 31	Do you think it's worth a shot to try and bend out? __________________ 2014 Hawk 250
	0

10-03-2017, 10:24 PM	#35
Andizzle Join Date: Sep 2017 Location: Lubbock Texas Posts: 31	I moved the shift lever down a notch and left off the belt cover so it would be free'd up. i tried sitting on the bike and bumping it back and forth to see if it would shift past 2nd. It didn't. So I decided to take it down the block to see if maybe running it would once I got 4 houses down this happened. __________________ 2014 Hawk 250
	0

10-03-2017, 10:28 PM	#37
Andizzle Join Date: Sep 2017 Location: Lubbock Texas Posts: 31	I'm guessing the shifter pawls ended up falling off the studs, and now it's stuck in neutral because it fell off. Does that sound right? __________________ 2014 Hawk 250
	0

10-04-2017, 01:15 AM	#38
Andizzle Join Date: Sep 2017 Location: Lubbock Texas Posts: 31	Jerryhawk250 sent me a service manual with the same engine, and in the transmission troubleshooting area, I found a page that gives me some ideas to what could be messed up with it. TROUBLESHOOTING Hard to shift • Incorrect clutch adjustment • Damaged shift drum cam groove • Bent shift fork • Bent shift fork shaft Transmission jumps out of gear • Worn gear engagement dogs or slots • Damaged or bent shift fork • Bent shift fork shaft • Damaged shift drum stopper arm • Broken shift linkage return spring • Damaged shift drum grooves Excessive noise • Worn connecting rod big end bearing • Bent connecting rod • Worn crankshaft main journal bearing __________________ 2014 Hawk 250
	0

10-04-2017, 08:18 AM	#39
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,552	I'm assuming you bent the shift lever so it doesn't hit the case any more allowing you to upshift completely and not hit anything. if so then you definitely have something not meshing up in the transmission. I would pull the right side cover off and inspect the camplate and selector plate area since that would be the easiest to get to and probably one of the first things to be damaged. Did you adjust the clutch yet? On these bikes you can't have too much play in the clutch are you will have trouble shifting. __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
	0

10-04-2017, 09:13 AM	#40
Andizzle Join Date: Sep 2017 Location: Lubbock Texas Posts: 31	Yes I adjusted the clutch and it wasn't pulling anymore. As soon as I tried to ride it without it hitting anything then that's when it slipped out of gear completely. I'll go ahead and pull the cover off then. Is it the right side of the bike if you're sitting on it? __________________ 2014 Hawk 250
	1

10-04-2017, 10:33 PM	#43
Andizzle Join Date: Sep 2017 Location: Lubbock Texas Posts: 31	I'm gonna try to take it off tomorrow it's been raining most of the day here. I already got the rear brake pedal off so I can get to the cover bolts easier. And I took of the clutch cable at the bottom. After that, I'm going to need to drain the oil and then take the cover off, right? __________________ 2014 Hawk 250
	1

10-05-2017, 07:30 AM	#44
Mudflap Join Date: Sep 2014 Posts: 1,870	You can drain the oil or lean the bike way over to the right so the oil will go to the other side of the engine.
	1

10-05-2017, 08:58 PM	#45
Andizzle Join Date: Sep 2017 Location: Lubbock Texas Posts: 31	Ok so I got the cover off I'm not exactly sure what I'm supposed to be looking for so I just took a video of the inside of it to give you an idea. __________________ 2014 Hawk 250
	0