Hawk 250 Nuetral & Transmission Problem

[JerryHawk250]

After reading the other post. If its still pulling with the clutch lever pulled Your clutch needs to be adjusted. You shouldn't have more than an 1/8 inch of play in the lever.

[Ariel Red Hunter]

Originally Posted by JerryHawk250

1st thing I notice is that the shift lever is hitting the housing. Remove the lever and rotate it counter clockwise 1 groove on the spline. It's not shifting all the way to 2nd gear. The shift lever is bent in to far and really should clear the housing.

Yes! The shift lever is hitting the cases on the up shift. It is not allowing the ratchet and pawls to go through their cycle so he can shift to the next higher gear. It may be only partally engaging second gear. Don't ride it like that, it will wear the dog clutches in the transmission....ARH

[Andizzle]

Originally Posted by JerryHawk250

1st thing I notice is that the shift lever is hitting the housing. Remove the lever and rotate it counter clockwise 1 groove on the spline. It's not shifting all the way to 2nd gear. The shift lever is bent in to far and really should clear the housing.

Ok. Do I have to take off the chain cover or should I be able to just undo the 10mm bolt that clamps it down and adjust it?

[JeremyC]

Yeah, that shift lever may be part of the problem, or all of it.

[JerryHawk250]

Originally Posted by Andizzle

Ok. Do I have to take off the chain cover or should I be able to just undo the 10mm bolt that clamps it down and adjust it?

you will have to remove the bolt.

[JerryHawk250]

When you have the lever off put it in a vice and bend it out some so it will clear the case when you put it back on. Don't try bending it on the bike as you might bend the shaft.

[timcosby]

also needs clutch adjusted after you do that bending. with the bike off and in first gear adjust the clutch until the bike rolls freely with the clutch lever pulled all the way in. the grinding while trying to go to first gear while running is cause the clutch is partially engaged from not being adjusted correctly. maybe look at some vids on youtube about clutch adjustment

[timcosby]

just watched your vid and when you say its gets stuck that looks like it is when you try to go to third. most of the time the bike has to be rolling a little bit to go thru the gears even when coming up on a red light and going back down thru the gears if i wait to do it while stopped some of the gears will be difficult to get to engage. what your showing in the vid may not be a problem cause its not moving up at all but i think thats because the bike is not rolling. when it does go up it looks to be hitting the case so its needs bent or rotated on the splined shaft.

[Andizzle]

Originally Posted by JerryHawk250

When you have the lever off put it in a vice and bend it out some so it will clear the case when you put it back on. Don't try bending it on the bike as you might bend the shaft.

Video 2

[Andizzle]

Originally Posted by timcosby

just watched your vid and when you say its gets stuck that looks like it is when you try to go to third. most of the time the bike has to be rolling a little bit to go thru the gears even when coming up on a red light and going back down thru the gears if i wait to do it while stopped some of the gears will be difficult to get to engage. what your showing in the vid may not be a problem cause its not moving up at all but i think thats because the bike is not rolling. when it does go up it looks to be hitting the case so its needs bent or rotated on the splined shaft.

It won't go into third while riding either it gets stuck exactly like in the video.

[Megadan]

Put a thin flat head screwdriver between the 2 halves that the bolt goes through to sperad it apart a bit and it should come free.

As far as the bike pulling in gear, that is entirely the clutch adjustment. Google tt250 clutch adjustment and you will find a CSC write up on how to adjust the clutch
. Follow that and you should be golden. Most of the adjustment is done on the motor side, and the fine tuning should be done at the lever end.

[timcosby]

Originally Posted by Andizzle

It won't go into third while riding either it gets stuck exactly like in the video.

probably cause the clutch isnt fully disengaging

[timcosby]

Originally Posted by Andizzle

Video 2

yea that lever is bent way up under there. you can even see the road rash on the end where he crash it.

[JerryHawk250]

Originally Posted by Andizzle

Video 2

As Megadan stated. Put a thin screwdriver between the 2 halves that the bolt goes through to spread it apart. That lever got bent in pretty far. Bend it out far enough to clear the case and you should be good to go.

[Ariel Red Hunter]

Originally Posted by JerryHawk250

As Megadan stated. Put a thin screwdriver between the 2 halves that the bolt goes through to spread it apart. That lever got bent in pretty far. Bend it out far enough to clear the case and you should be good to go.

Yes, the lever is bent in too far. But don't try to rebend it on the bike. Tap that screw driver, or whatever you were using in the video, just enough to get it free enough to get it off. Then bend it back out, or buy a new one. I think CSC has them. There are guys on here that can post a link to CSC, if you decide to go that route. When you bend it out, make sure you bend it out enough to clear the outside of the case by a 1/4 / 3/8ths of an inch. It must not touch the case anywhere in its travel. Let us know if that fixes it. If it does, than we will get to the clutch issues....ARH