Shifting Problems

[Davescycles72]

It appears we have the exact same year with exact problem did you ever get anywhere with not shifting past neutral?

[BowlingSS]

I am still working on it. Been out of town.

[BowlingSS]

Shifting is working great now. Replaced 2nd gear, shifter fork rollers, and cotters.

[Tim Allman]

These bikes have known problems with second gear. When you shift to 2nd the dogs on the side of the 2nd gear on the mainshaft should engage, leaving very little space. However, a bit of wear can leave the transmission prone to jumping out of 2nd. This is fixed by replacing the zero offset gear cotter (90602-250-010) with one with 0.5 mm or 1.0 mm offset. These may still be available.

So if you can see the 2nd gear slide on the shaft as you rotate the shifter drum but without engaging the gear next to it properly this is likely the problem. I'm not sure what else it could be.

It appears the the shifter forks are in good condition.