74ossaguy Posted August 8, 2011 Report Share Posted August 8, 2011 I have a 2002 280 pro that has seen a lot of riding time. I am the second owner. The first was a top calibur rider who probably rode it hard. I am having trouble with the shifting function. It has the case modification where case material was removed to enhance the shifter spring throw- more travel. The engine was torn open once recently to inspect and most all looked really fine. After adjusting the shifter concentric cam 4 times (ugh)I have it down to one problem. When shifting down from 3rd to second gears it does not seem to engage the second gear. Instead it just goes into like a nuetral area of sorts and thus it is not in any gear. The only solution is to attemp to shift back up to third and then try to down shift once again. It down shifts into 2nd gear about 30% of the time. The rest of the time it wont engage and you can only upshift and try again. It does feel like there is some pressure or something binding on the shifter shaft when it goes in this false nuetral spot. All other shifts perform fine. Would you expect bad foks, worn gear dogs, or a probelm with the shifter selector? Any help would be greatly appreciated. Quote Link to comment Share on other sites More sharing options...
peterb Posted August 9, 2011 Report Share Posted August 9, 2011 Hi osssaguy, If you are unable to adjust this out using the eccentric adjustment, then there may be one of two problems, one, it is likely that one or more of your selector forks have bent. The 02 model was a problematic year, some motors required the selector shafts replacing and the 3 selectors as some shafts were found to be non-concentric and the forks were not properly heat treated. You can check 2 of the forks by eyesight, holding them back to back to see if they are square, eg; no daylight visible between them. Later forks are more solidly built. Two, it may just be something rather simple like the shift spring retainer, which is a top hat shape, at the top is a strip that engages into the end of the shift shaft, at the bottom is a separate pressed on piece that has a tab for the spring to engage on. Sometimes this top hat unit can separate or twist around slightly causing the problems you describe. You can braze this together carefully, or put a new one in. Bye, PeterB. Quote Link to comment Share on other sites More sharing options...
74ossaguy Posted August 10, 2011 Author Report Share Posted August 10, 2011 Hi osssaguy, If you are unable to adjust this out using the eccentric adjustment, then there may be one of two problems, one, it is likely that one or more of your selector forks have bent. The 02 model was a problematic year, some motors required the selector shafts replacing and the 3 selectors as some shafts were found to be non-concentric and the forks were not properly heat treated. You can check 2 of the forks by eyesight, holding them back to back to see if they are square, eg; no daylight visible between them. Later forks are more solidly built. Two, it may just be something rather simple like the shift spring retainer, which is a top hat shape, at the top is a strip that engages into the end of the shift shaft, at the bottom is a separate pressed on piece that has a tab for the spring to engage on. Sometimes this top hat unit can separate or twist around slightly causing the problems you describe. You can braze this together carefully, or put a new one in. Bye, PeterB. Quote Link to comment Share on other sites More sharing options...
74ossaguy Posted August 10, 2011 Author Report Share Posted August 10, 2011 thanks for your advice. I have the gearbox apart and forks look suspect. I will see Quote Link to comment Share on other sites More sharing options...
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