No neutral

[nigmax]

Alright Suzuki GURU'S i need help,
Story is, test riding 81 465 new top end haven't touched bottom, going great shifting well all is tight, pull up and put
in neutral all good couple of revs while standing next to bike, bike drops out of neutral lands in gear and luckily stalls.
Had to drag bike onto trailer couldn't even freewheel with clutch pulled in.
So far i have checked shift detent ie sump plug, was loose but not out any threads, lined the shifting gear cam up to neutral replaced detent
no good, taken clutch basket of removed gear shift shaft lined up replaced basket no good.
I seem to be able to line everything up find neutral then as soon as i put clutch assembly back on no good.
I'm going mad tell me i'm an idiot and its a simple fix.

Cheers
Nick

[nigmax]

HEEEEEEEEEEEEELLLLLLLLLLLLLP

[David Lahey]

Is the centering spring for the shifter shaft set properly? Some bikes need this adjusted to work right.
Another thought - has it got an unusually heavy or long shift lever?
Is it leaning over a bit when it happens?

One of my bikes has an odd problem similar to this but it doesn't bother me much as I only ever use neutral when I'm starting it from cold, and it doesn't ride away then because I am sitting on it. My bike with this problem (KT250) jumps into gear if you lean it over to the right (with motor running or stopped).

[nigmax]

Hey mate,
the spring shaft seems to line up and sit fine and it seems to be the original shifter which doesn't seem to long.

Cheers
Nick

[Doc]

do you have the spacer (cushion) that fits on the shaft between the seal and gear lever fitted? If not the shaft can move inwards and off either of the centering spring locating pins.

[nigmax]

Hey Doc,
Yeah mate i made one up for this bike as i had stolen the original for my another one,but i will double check for excess movement.

Cheers
Nick

[OverTheHill]

without thinking 'too hard' as 'too late' over here, sounds like a gear has picked up [seized] on a shaft & is just driving through that rather than dogs locking it in. Suppose even the kick start idler gear seizing could do it too [i.e. lock one shaft to the other] or i suppose lock it right through to the crank that way even with the clutch pulled in!!. Interested to know the outcome & will keep watching, goodluck. ps, anything like that is usually due too 'lack of lubrication'. Not being too familiar with suzukis maybe they have needle bearings for gears to spin on which would make my ideas less likely--but anyway, see how ya go.

[OverTheHill]

just add something in reverse to the 'no neutral bit' my boy had 6 neutrals [7 i suppose] on his yzf250 [modern 09] & had ripped the splines out of the clutch centre.