Hello I have pre unit gearbox without the engine running all gears select fine without use of the clutch, touch the clutch and it will not select 4th gear going up the box or 2nd going down, the same problem exsists withe the enging running and the bike rolling in gear, I am told the gearbox has been completely re built with all new bearings and seals etc, it is fitted to a triton with a new belt drive primary drive, all the other gear changes are quite smooth and easy to select 4th and 2nd can be selected with considerable pressure if you dont use the clutch Regards Albert.

SOURCE: gear change down sticky

clutch plates are sticking has nothing to do with lever replace your clutch plates

SOURCE: i have a 1996 kx 250 that will not select 4th gear

Selecter forks could be damaged, gear shift shaft bent, return spring faulty, clutch dragging maybe! Try rocking it backwards and forwards engine off and see if you can find that gear! Good Luck - The Yeti

Chris Spudulike

• 63 Answers
• Posted on Aug 31, 2009

SOURCE: 1957 pre unit inner chaincase felt washer position

Inner chaincase has sprungfork plate rivited on, between which you should have a large plain washer and felt washer that are in situ before inner case is located over GB mainshft. if you have the projecting brass sleeve (bearing) this will fit inside felt/washer on assembly. Its not critical and you wont lose a lot of oil even if you dont use the above.

SOURCE: engine cuts when selecting 1st gear

disconnect side stand switch to check if that is faulty

Testimonial: "thanks, was faulty wiring. Replaced & Cleaned Push Switch. All Fine Regards"

SOURCE: Can select 1st gear and 2nd gear but am unable to

The gearbox does not need to be relpaced. The bike has a bent shift fork. The engine comes out then gets a complete tear down to get to the bad fork. This will probably cost $1200 or so. Call a dealer and get an estimate. Please rate my answer. Thanks.

Testimonial: "Thanks very much for your advice and help!!!!! much appreciated!"