Can't select neutral/Shift cam question.

[Banwen]

Hi all,
Iv done a bottom end rebuild on myEc250 and can't find neutral... Going through all gears fine but no natural. What I want to know is there a right way the shift cam has to be reinstalled? I read that I need to turn it 180???? Can you adjust the shift cam without splitting the engine? Thanks in advance.

 

[gasgasman]

The shift drum is not timed correctly.
The case will have to be split to reset.

When you split the case, leave everything on the right side and shift through the gears.
You'll see where the issue is.

Look in this manual.
Has the shift drum orientation.
Next time, take lots of pictures.

https://www.dropbox.com/s/i93vw77r9kuszxs/gasgas%20workshop%20manual.pdf?dl=0

 

[Gasser Nate]

Not necessarily, make sure the star on the end of the shift drum is sitting on its locating dowel correctly. You should always cycle through the box to make sure all your gears are selecting properly before assembling the rest of the motor too.

 

[Banwen]

Much appreciated boys, I'll split tha engine today. Thanks again.

 

[Anders]

Not necessarily, make sure the star on the end of the shift drum is sitting on its locating dowel correctly. You should always cycle through the box to make sure all your gears are selecting properly before assembling the rest of the motor too.

Indeed. I think if you have all the 6 speeds in the correct sequence, the error may likely be in the selector mechanism. I would check there before splitting the cases again.

I assembled my engine yesterday. Picture below. My box is placed in neutral. The star at the end of the shift drum is locked by the spring-loaded roller. In the neutral position, one of the peaks of the star faces the roller (arrow). Perhaps your spring-loaded "locator" does not lock it when in neutral?

 

[Gasser Nate]

My apologies Anders, ignore my post. I was remembering one off the two piece shift drums. I have had a few motors apart in my life!

If you pull the clutch cover so you motor appears like the above photo. You can remove the shift shaft entirely and turn the shift drum with a Allen key to check whether the gearbox is assembled correctly. If all is good refit the shift shaft and check.

If not you may have inadvertently flipped a gear which is now not allowing neutral to be selected. If you do need to split it make sure the shift forks are in their correct location. Also make sure the little gasket piece above the hole for the reed cage stays put now it is cut free.