[brettmoto]

Hi there I'm Brett and iv got a 2011 250f,iv got a major problem with my gearbox,I was out riding and the bike wouldn't go in gear so I split the cases and found the single gear fork selector snapped in two, it also had cutting marks where the gear was rubbing/cutting,myself and my mate have been through it for three hours tonight and carnt come up with anything I'm hopping that any of you guys have had a similar issue and what they did to fix it,thanks Brett …

[JimDirt]

When you say you were riding and it would not go into gear , can you be more specific ?? , like it was working fine , then you shifted into first from a stop , or you shifted from first to second ??

Did you have a crash/fall , on the shifter side prior to the bike not shifting , where the shifter might have been jammed up or down real hard ??

Had the engine recently been gone thru , where the tranny could have been assembled wrong ??

Was the tranny oil level low ??

Its kind of uncommon for a shift fork to just break , there had to be something done leading up to this

[brettmoto]

Hi Jim ,yes the motor had been gone through,I put a new 3rd & 5th gear and fork selector in the gear box about 4 hour ago,the old fork was bent and had scoring / cutting marks around the back where the gear was in contact with the fork.
I also fell on the the foot gear shifter about 3 hours before but seemed the be ok.
I need a drawing/microfesh of the gear box the check iv got everything in the correct order.

[JimDirt]

Yea its possible that you have a shim or 2 in the wrong location and its pushing the fork over too far , or it has the entire shaft pushed over and that is creating your issue , you should be able to align everything when its all in one case , so you should be able to see if its not seated all the way because of a extra shim , so when you lay the one case on its side and install all the gears , everything should line up , all gears should be EVEN , if anything looks like its offset , then that might be the problem ...

Unfortunately the only way to be sure everything is good , is to replace ALL worn/rubbed/bent parts , so your not trying to align against worn parts , but in the end , every gear when in place (shift thru gears to check alignment in each gear) should ride centered with each other , if not , you need to move shims around , you should not have to add any , just measure how far its off and find the appropriate shim to get it back into position in the proper place on the shaft

I personally (will take time) , would set everything in one case , check alignment , then transfer everything into the other case , this should show where its offset , then the shim should go where its low and not where its high , as it will be off in one direction on one side , and the opposite in the other , when you find the one thats off , that should solve your problem (hopefully that made sense)

[brettmoto]

Ok thanks I'll give that a go and I'll post back on hear