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My fzr 250 jumps out of gear at least once everytime I ride it and just sits between gears until I change gear again is it worth taking the gearbox appart to try and fix it or would it be better to just get another gearbox
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If it jumps out of gear then the drive dogs on the side of the gears in the gearbox are worn and need replacing along with the matching drive or driven gear.the oil type is 10 w 40 only use this and also make sure it not fully synthetic or the clutch will slip.
a gear box place should know more than me but this can also be caused bye a little ball bearing and spring .... these 2 things push on the selecter shafts and fit in to a groove that holds the shaft in the right spot .. that is what u feel when u change gear and it stays in position ....... the spring - springs can looz tention .. brake or the ball can wear or the groov it sits in to can do the same making it not hold in position ... 2nd and 4th are prob on the same shaft and this problem useully happens under load or taking off quick ........ i think they call them retainer springs and ball
The bike has a slightly bent shift fork. The slider gear that engages the second gear wheel is not fully engaging because of the bend. You must remove the engine from the frame and yes, the lower case half will need to split from the upper case half. You will not need to tear down the top end at all unless you choose to replace the rings. An observation; you are a brave man, a very good mechanic, or someone seeking adventure if you install new rings. There are a lot of parts and the cam chain re-assembly leaves no room for error. I would do it, but then again, I have 42 years of experience. Please rate my answer, Thanks!
Assuming the drive chain and sprockets are in good condition.(check these first)
This sounds like and internal gearbox problem, a bearing has collapsed or a tooth has broken of a gear.
Riding it like this will cause more damage. The gear box will likely need to be stripped
If the clutch lever is properly adjusted, this is normally what happens if the gearbox oil is extremely dirty. Do and oil change then ride for 30 minutes. Then change the oil again to help flush out the dirt. If that doesn't help, then the clutch pressure plates are warped or the cork on the fiber friction plates is swollen from using synthetic lubricants in the gearbox. Check the plates and replace as needed.
pull your clutch in on the left handlebar push the shifter lever down and let you clutch out slowly while giveing the bike a lil bit of gas. But if you don't know how to ride i wouldn't be jumping on a kx 250
If you take it to mercedes they will charge £3500 and will replace the gearbox, Alternatively you can change the shifter valve £25, new sump and filter as they have changed, fit a magnet inside the gearbox as the early A didnt have one. Fresh oil and see how you get on, the control unit for the gearbox sits inside the gearbox £1000 roughly for a new one but it has to come from mercedes in germany where it is coded to your chassis number, 2nd control units are not an option!!!!!!!
jib www.mercanic.co.uk
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