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gt5094stang

1986 Suzuki LT230s Not shifting

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hey guys need help asap........got an 86 lt230s that i just put a new crank in. i put it all back together and tryed to shift gears and it feels locked up. took it apart to make sure nothing was installed incorrectly and nothin was so put the crank case back together and tryed to shift it and it still wouldnt shift. dont kno what to do or how else to aproach this. even befor i put the case together i manually made sure the trans shifted through all the gears even through revers and it did until i put the case together. any ideas?????

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no debris or any crap inside the case locking up the gears...wen u put it together did it slide on well or was it a little difficult to put on did u force it on?

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What happens when you debress the clutch? Is the shift lever going through the gears with the atv off?

* Edited your thread title so it will be found better.

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The tranny can be very tempermental if anything is even slightly off. Every little washer and spacer is a different size or width, and they MUST be in the right spot. I don't know how far you disassembled, but you will need to go back over everything you had apart and double and tripple check everythinguntil you find the problem. The first an easiest thing to check is the ratchet mechanism on at the end to the shift shaft. Check that stuff first as it will not require splitting the cases just remove the clutch side case cover, you will probably have to take the clutch out too, something may have just slipped out of position when you were putting it back together. If that is all ok, then you will have to get back inside the crankcase. Make sure the shift forks are in the right spots. Check to see if all the gears are lined up properly, turn them around and make sure they don't catch or stop, they should turn all the way around without interference. I lost track of the washers in my CR 500 motor and had to buy all new ones so I could reference the part #'s and find out where they go using a Honda part fische diagram. That was a real pain. Good luck.

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ok didnt realize this but a buddy of mine helped me out with the issue i was having and i guess i had everything correctly installed but in order to shift the crank has to be moving. shifted just fine after but as soon as you stopped moving it itll lock up again....... is this normal that internals have to be moving in order for the tranny to shift????

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I would say that is not normal, you should be able to shift at any time. Take the plug out and roll the motor around by hand, you need to make sure that everything rolls smoothly and you don't want to hear any clicking noises like two objects catching edges as they pass each other. If every thing rolls together ok it might just be a worn shift fork or fork shaft, that could cause the bike to not shift unless things are moving.

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