[Marcoz88]

Hi at all,
i have a crf 450 R 2003 motard and i've a new fresh problem.

After a complete rebuild of the engine, and the revision of the transmission with the repair manual (also the forks thicketness and the gears integrity and the total replace of bearings and seals) i've used the bike for 35 hours in the mountain street (so the crf wasn't stressed) without any type of problems.
My actual problem is that in random time, when driving, if i go from the 2nd gear to first gear, sometime the shift pedal remain blocked in the first position (if i want to take the 2nd gear, the pedal doesn't move).
The first time, i tried to power off the bike and check the pedal and move the bike but the it remains blocked. In the end i power on the bike with the clutch pulled and after 2-3 seconds the pedal is released normally (and the transmission went normally without any kind of problem).

Again, in a second day when driving, i had the same problem but after 2-3 seconds of driving, the pedain is released.

This problem is occasionally, but when the problem doesn't occur the transmission works very well without strange noise or hangs!!

I use the Bardahl gear oil.

What do you think the problem could be?

I need to reopen the entire engine again?? or is possibile to be a problem in right side of crankcase?

Thank you very much and sorry for my bad english

Marco

[JimDirt]

Have you verified on the clutch side that the drum actuator is not bent or installed incorrectly , since this is the first step in the shifting , from the shifter it goes to the shaft and the shifter drum actuator (Part#9,#18,#14,#16), so that is where i would start

http://partsfinder.onlinemicrofiche.com ... SHIFT-DRUM

, if its not that , then you might have a bent fork and it hangs once in a while , so try the actuator first , if not it , then your only option is to tear into the tranny again

Oh ! , and Welcome to the site !!

[Marcoz88]

Thank you very much Jim, i've only the fear that, if i check the actuator when the gear isn't blocked, the problem is not noticable.

the very strange fact is that the gear is perfect (a part this random problem), i find the neutral immediatly, and the gear work good.

Thank you again

Marco

[JimDirt]

The next time it locks up , pull the side cover and look to see if the actuator is popped out or gone past where it should , this would be my first guess , if it checks out ok while its locked up , then it has to be in the transmission