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Hi guys looking for help on 07 crf250r after bottom end rebuild while riding changing into 4th gear it goes to neutral when i put the trans together everything spun freely on shift drum checked the shifter mechanism seems to move when gear shifter moves
Cheers tim

Welcome to the site !!

Its possible that you have some shims in the wrong place ?? , or you have the shift drum/forks installed incorrectly ?? , or they were worn and upon re-assembly the issue got worse because of a shim misplacement ?? , sometimes just 1 shim in the wrong place will offset a gear enough to cause this , especially if the gears had any kind of wear on the cogs , if they have any rounding to them the gear will not go all the way to the other and slip back and cause it to pop out of gear

Also , on the clutch side the sift actuator could be mis-aligned or bent , or the spring not seated properly , what started the issue ?? , it was shifting fine , then it just started skipping 4th ?? , or did it do it from the first after re-assembly ??

Did you by chance drop the bike on the shifter ??

Any of these things can cause your issue , if it worked fine before , then it has to be something you did during assembly

A little more detail as to what happened , like it was working fine and you were speed shifting (without the clutch) and jammed the shifter , or you fell on that side and jammed the shifter , or it did it the first time you rode after rebuild and does it every time , or just occasionally , were you riding easy (trail riding) or at the track ?? , was it on the first ride , or after several uneventful rides ??

But i am guessing the issue will be in the shift drum , or on the clutch side with the actuator , or a worn cog (the fingers that stick out of the gears)

It was on first start up after rebuild and im pretty sure none of the shims come of or moved

You could have put one on the opposite side and it moved everything over far enough to cause the issue , if it was not caused by a crash , then the only other options are a assembly mistake , or a worn shift drum or gear cog or shift actuator

Thanks mate ill pull down it on the weekend

Ia there anyway to figure out what washers go where

I would look more at worn parts than shims , as that is what i am thinking is the main issue , the shims should only be sized for each shaft so they should not be easy to mix up , but it can happen

This is a chart from the Factory Honda Service Manual ,it gives you all the service/wear limits of the transmission components



This is a list of common issues when a transmission pops out of gear



Hope that helps some