ec250 stuck in gear

T

thelonius

New member
Went riding yesterday. Nothing unusual until my ec250 got stuck in 2nd or 3rd gear. When I got back to the truck and tried to shift it by hand, I noticed that there was no feel, no "click" to it. Any ideas? This bike only has about 12 hours of slow, easygoing riding on it. Could this be something substantial?
 
Sounds like the mechanizm on the end of the shift drum, maybe the screw backed out and the shifter wont catch it, pull the clutch side cover, and you will be able to see the end of the drum.
 
This problem is not uncommon to new gassers. The shifter shaft goes all the way through the motor to the right side just aft of the clutch. On one end of the shaft is the shift lever and on the other is a flat plate (about 1x2.5 inches) that has a strong spring attached that returns your shift lever to center. That flat plate is called a scorpion because it's shaped somewhat like one. The scorpion is designed to slide back and forth and it sounds like yours is stuck. The scorpion is a stamped steel part and some come out just a little rough and will stick after the oil gets dirty. I had this problem with my 07 bike. Good news is its easy to fix with some sand paper and maybe a file. Take the crank lever, shift lever and right side cover off then the parts you need to work on will pull right out of the right side. Smooth all the edges as well as you can possibly get them and not only will you never have that problem again your bike may shift a letter better as well.
Others have posted on this before so do a search for a better explanation using the word: scorpion.
 
If you do the search on the word: scorpion there is a good picture as an attachment to the first thread on page 2 of the results. The thread is by "rupecopp"
 
Gasser-thanks so much. I think this is the problem, though I won't know for sure until I put a new gasket on and get it off the trailer. However, I am still
having a hard time understanding how a little debris can get hung up on the rough "edge" and cause enough drag to make the scorpion stick. I could understand if the main surface of the scorpion that came in contact with the other flat metal piece was rough, though. But I'm no mechanic...
 
The parts are stamped, and one is welded to the shaft. The edges, occasional spatter, and slight warpage vary from part to part and can cause sticking if bad enough. I take it out on a new bike and make sure the parts are true, then dress the sliding surfaces with a fine file and a stone. Never a problem.
 
sounds like the small spring on the shift drum has broken locking the bike in a single gear. this has happened to me before and I now carry a spare.
 
Should one do this before even riding a new bike? Sounds like one more thing to add to the list of new bike prep. If you're gonna tear down the chassis to do all the bearings, you may as well pull this Scorpion thingy out and dress it up too.
 
Thats my philosophy exactly. Address any potential problem areas up front so they don't ruin your day later. While your at it check the clutch basket and friction plate fingers for burrs.
 
When I get my next new gasser I'll take care of the scorpion during the first oil change. That way I can clean out all the little shavings that result from the initial break-in.
 
Oh, man am I getting frustrated. I took off the scorpion, smoothed it out, reinstalled it and everything seemed fine. With the clutch cover off, I was able to put the bike in neutral and first gear with my hand on the gearshifter. Repeated this several times. Put cover back on and bike is goofy like before. Took cover back off, everything fine...etc. What is going on here?
 
thelonius said:
Oh, man am I getting frustrated. I took off the scorpion, smoothed it out, reinstalled it and everything seemed fine. With the clutch cover off, I was able to put the bike in neutral and first gear with my hand on the gearshifter. Repeated this several times. Put cover back on and bike is goofy like before. Took cover back off, everything fine...etc. What is going on here?
Click to expand...

You would assume the cover is interfering or tightening on the setup somehow.
This is what I would be looking at anyway without really knowing much about the actual setup.
Something is putting tension where it shouldn't be.
Cheers Mark:confused:
 
Shaft is not bent. This bike is virgin. I will try and post pics so you guys can tell me if I have reassembled it properly. Look for those pics in the next 24 hr. Otherwise I may have to take it to the GG mechanic in Knoxville, which is going to amount to 400+ miles of driving by the time all is said and done.
 
If the parts are smooth and square, something is not assembled correctly. First guess would be the spring and centering bushing on the scorpion. The assembly has to be fully seated into the case, with the pin through the slot and between the arms of the spring. Also, is the detent arm bolt tight? I'm pretty sure I have some good photos of this I took this winter when I did my starter gears, before my camera self destructed.
 
Got the bike to shift now. Problem was that I did not have the centerer pushed in far enough. New problem: bike will shift, but gearshifter will not return to center. What the hell??? The spring looks taut. Gasser, can you help?
 
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