2002 trx250ex shifter concern..? - Honda TRX Forum
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post #1 of 15 Old 03-21-2019, 12:49 AM Thread Starter
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2002 trx250ex shifter concern..?

2002 trx250ex has a faulty stator removed the rear cover installed stator.... note atv ran fine before replacing stator would lose spark at half throttle and up. Now shifter is all the way down and will not shift it is stuck in gear so I am unable to start so I removed the clutch cover and inspected all under there by the manual and all looks normal.....??? Need help please anyone every had this happen before?? Any help at this point would be greatly appreciated!!??..
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post #2 of 15 Old 03-21-2019, 01:27 PM
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You have to hold the shift shaft so the shift pawl enters the operator on the sub-shift shaft as the cover is installed - see page 11-9 of the service manual - failure to do so will result in shifting in one direction only if at all
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post #3 of 15 Old 03-21-2019, 02:52 PM Thread Starter
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I made sure several times that the shifter was in the hole as show in the picture when all together shifter is bottomed out and will not shift up at all
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post #4 of 15 Old 03-21-2019, 03:04 PM Thread Starter
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Note when cover off tried to operate shift rod and it will not move down it is against the lower housing does have play upward but will not shift.....
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post #5 of 15 Old 03-21-2019, 10:27 PM
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If the part #14 in the pic has the ball and pin as pictured, then the problem has to be on the other end - by any chance did the shift shaft (under the pen in your pic) pull out when you pulled the rear cover off? It has to be timed on the end under the clutch cover.
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post #6 of 15 Old 03-21-2019, 11:24 PM Thread Starter
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Not sure.... I will check that and get back with you.. thanks for the help.. I am lost on this one lol
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post #7 of 15 Old 03-22-2019, 12:19 AM Thread Starter
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I didn't take the #14 apart and the shaft has a snap ring on the end under the clutch cover...
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post #8 of 15 Old 03-22-2019, 12:53 PM
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The parts breakdown does not show a snap ring on the end of the shaft under the clutch cover - it depicts one snap ring on the shaft that keeps the shaft from pushing forward when the front cover is off - there should be a thrust washer against the engine case and a snap ring on the shaft on the rear of the engine, but I don't see a snap ring on the clutch end
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post #9 of 15 Old 03-22-2019, 02:15 PM Thread Starter
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The shifter shaft would not move or pull out from under the stator a c snap ring holds it
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post #10 of 15 Old 03-23-2019, 04:29 PM
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That snap ring goes in a groove way down the shaft - you put the snap ring on first followed by a thrust washer then insert the shaft into the engine case - then the rear cover goes on before assembly of the clutch end
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