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Old June 6th, 2018, 09:46 PM   #1
halfassmech
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Name: Warren
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issues with shifting/neutral light. PLEASE HELP!!

Bought a 09 250r to mess with. I absolutely love bikes and working on them, so I buy them messed up so I can learn everything I can. So far out of the 10 or so bikes ive flipped I haven't seen this. I bought this bike from a gent that couldn't get it to shift after replacing the clutch plates. After taking off the clutch cover and looking at the plates, only thing i could come up with was they looked different from the OEM plates. After ordering the OEM plates and installing them i can get the bike to shift but not into first. the neutral light comes and goes even though its in neutral. when the light is not on i have to pull in the clutch to start it, even though its in neutral. It will shift to second but you really got to pull up on the lever. once its in motion and riding it shifts great, still wont go to first though. he says he didn't take anything off but the clutch plates and the cover............. idk about that now. Anyone have any ideas?? please
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Old June 6th, 2018, 10:03 PM   #2
halfassmech
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also when I put the clutch cover back on there isnt resistence on the lever that attaches the clutch cable. pulling the clutch lever does disengage the clutch, but shouldnt the clutch cable be very tight from the springs behind the clutch housing plate? If i remove one plate from the clutch it acts like i think it should, the springs deffently have resistence when attaching the cable back to the housing. im not able to just do it by hand then. first time ever opening up the clutch cover!!
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Old June 6th, 2018, 10:21 PM   #3
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Is outermost plate different than others?
Are basket fingers smooth on edges?
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Old June 6th, 2018, 10:43 PM   #4
halfassmech
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Quote:
Originally Posted by DannoXYZ View Post
Is outermost plate different than others?
Are basket fingers smooth on edges?
Yes i made sure the inner and outer plates are bigger then the center plates. I have the service manual and have read every word on the clutch plates over and over.
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Old June 6th, 2018, 10:44 PM   #5
halfassmech
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Quote:
Originally Posted by DannoXYZ View Post
Is outermost plate different than others?
Are basket fingers smooth on edges?
Im not sure what basketfingers are?
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Old June 6th, 2018, 10:58 PM   #6
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The outer basket fingers



Does yours have notches and steps?
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Old June 6th, 2018, 11:03 PM   #7
halfassmech
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Quote:
Originally Posted by DannoXYZ View Post
The outer basket fingers



Does yours have notches and steps?
I will check in the morning when i get back to it.
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Old June 7th, 2018, 12:12 PM   #8
halfassmech
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here are some pictures of what im working with. In one of the pictures im pointing to the half moon shape on the fiber disc, what is that for? I dont see any kind of place where they go or line up to. not real sure what they are for, nothing in the service manual about them.
Attached Images
File Type: jpg 20180607_134923_1528398503098.jpg (79.2 KB, 5 views)
File Type: jpg 20180607_140143_1528398502895.jpg (74.5 KB, 5 views)
File Type: jpg 20180607_140150_1528398503198.jpg (100.8 KB, 7 views)
File Type: jpg 20180607_140237_1528398502644.jpg (49.7 KB, 8 views)
File Type: jpg 20180607_140157_1528398502996.jpg (67.7 KB, 11 views)
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Old June 7th, 2018, 10:15 PM   #9
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This uneducated guess is that something is misaligned. The clutch thinking it's in neutral doesn't line up with the rest of the bike's opinion of where neutral is.
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