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Help FZR250 - trouble selecting neutral

Discussion in 'Yamaha 250cc In-Line 4's' started by 19pJoshrulz, Mar 1, 2021.

  1. 19pJoshrulz

    19pJoshrulz Active Member

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    hi all
    recently swapped a 3ln1 motor int a 3ln3 frame, everything runs fine except the difference between the oil level sensors and oil pressure sensor.

    However my main issue is finding it almost impossible to select neutral, have only tested it in the driveway, i noticed i am missing the gasket between the sprocket guard and block - not sure if that could cause a bind, it selects all the gears fine just not neutral.

    could it be something as silly as my shoes being too soft and not having the right feel, i can click it into neutral by hand - will confirm if this can be done with engine running in gear with clutch in and while switched off.
     
    19pJoshrulz, Mar 1, 2021
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  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    On a 3LN this is the optimal position for the linkage (blue arrow) , especially for neutral
    There is a "dot" on the output shaft as a guide


    Also u can adjust the height of the gear lever by undoing the lock nuts and turning the rod with your fingers ... 1 nut is a 'reverse' thread ... and grease up plenty under the rubber boots

    FZR gear lever 2.jpg
     
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    GreyImport, Mar 1, 2021
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  3. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Does it select easy with the engine not running? If so suspect dragging clutch.
    If not, time to get all of the play out of the shift linkage and lube everything.
     
    maelstrom, Mar 1, 2021
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  4. 19pJoshrulz

    19pJoshrulz Active Member

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    thanks for the tips, will adjust that linkage position - have attached a photo of it currently.
    Will also give all the moving parts some lube including the clutch cable/lever - maybe adjust the cable for a bit more travel.

    IMG_20210228_154045.jpg
     
    19pJoshrulz, Mar 1, 2021
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  5. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Definitelky on the wrong position there. Should be as Grey's photo. Make sure the clamp nut is tight, and the linkage nuts are tight. Any remaining slop is going to be wear/play in the rose joints and lever pivot.

    Ensure the clutch cable has enough free play - check steering at full lock either way, sometimes with the way they are routed and the number of bends can affect the free play when you move the steering.
     
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    Linkin, Mar 2, 2021
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  6. 19pJoshrulz

    19pJoshrulz Active Member

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    so re positioned the pedal as per Greyimport photo, can 100% confirm it will only go into neutral with engine off - can literally use my finger tips to do it. Should i be looking at the clutch now ? doesnt feel like there is any drag based on feel through the clutch lever.
     
    19pJoshrulz, Mar 7, 2021
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  7. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    I would say, yes. Amongst all the issues, clutch hubs suffering from the plates wearing notches in them, is one of them.
     
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    Last edited: Mar 7, 2021
    maelstrom, Mar 7, 2021
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  8. 19pJoshrulz

    19pJoshrulz Active Member

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    bit of an update
    clutch basket fingers had notches, so smoothed them all out, i also changed the entire shift rod seeing as i had a spare 3ln3 motor. Made no difference to selecting neutral, going to assume its something to do with the selector forks or the drum.

    20210313_154800.jpg 20210313_142632.jpg
     
    19pJoshrulz, Mar 14, 2021
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  9. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Is the drum supposed to be missing that chunk?
    As you said it selects neutral fine when the engine is not running. It is not the gearbox. The next thing to inspect is the detent springs and mechanism.
     
    maelstrom, Mar 15, 2021
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  10. manynathans

    manynathans Guest

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    Yup the short finger on the clutch basket allows just enough clearance to remove the basket past the cases without splitting the engine. Providing the centre boss and bits of the clutch basket are removed with a magnet first to create some clearance on the shaft.
     
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    manynathans, Mar 15, 2021
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  11. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Yes it is ... its for clearance when installing .... I think its the stator casing gets in the way ... its been awhile


    basket.jpg
     
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    GreyImport, Mar 15, 2021
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  12. 19pJoshrulz

    19pJoshrulz Active Member

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    the shift springs/lever and the star shaped piece appear to be moving and working - i wouldnt know what it would look like if it wasnt working correctly as the bikes previous engine was stripped.
     
    19pJoshrulz, Mar 18, 2021
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