i have a 11 rmz250 that wont shift into third.replaced most of the gears in tranny,all 3 shift forks,the pawls,the shift plate,both springs on the shift shaft,and the cam tension.basically all of it.when i shift it by hand the bike shifts fine until i go into 3rd.looks like the shifter doesnt return to allow the cam to move.really geting sick of this bike already.i can lift the shifter  and release it and it does nothing as if its not catching

oh, thats just new suzukis.
its a special feature they have decided to throw in since 2009.
it helps keep there parts sales up during these hard economic times...

thank you for proudly sponsoring suzuki motorcycle corporation.
next years model will come with soft valves for your riding pleasure.

thecount, on 27 June 2012 - 04:13 AM, said:

its hard to say since you have it all buttoned up, but you must have missed something on assembly. try looking back at the shift mechanism. did you disassemble the cam from the drum? are the pawls correctly in place (didnt get jammed up on assembly)? take the right side cover off and inspect the operation of the shift mechanism, get someone to actuate the shifter while you inspect whats going on with the ratched mechanism and cam. if its shifting fine through 1st to second and you find that the drum doesn't want to move any further (even with assistance), than unfortunately the problem lies between the cases. i ALWAYS check the shifting before i put the cases back together, and most likely something has been assembled wrong internally.

Did you work the problem out because I have the exact same problem with my brothers 2011 for 3rd 4th and 5th if u slighty push down on the gear lever i clicks on the star and then can shift up... shifts down fine. if u put a spanner on the end of the drum it shifts fine to it much be the shifting mechansim?

how many hours on the bike dude

not even 30... problem solved it had a bend gear lever shaft, only noticed it as it had small stress fractures in it. Not surprising seen as every gear had to be replaced....

bent gear lever shaft?! now that would have to be the first time ive heard of this. was it like that from the factory or are you stomping the living daylights out of the shifter? i could see that happening maybe after a fairly hard crash but still, cant say ive ever seen or heard of this before...

I should of been more clear its not the chrome rod part of the selector but the end piece on the clutch side that turns the drum which has obviously bent when the gearbox locked up, and no, no one has been stomping gears its my brothers bike and he is very steady lucky to even need to change up gears.... But I couldnt care less who was riding it in less then 30 hours a gearbox shouldnt smash itself to pieces there just crap bikes....

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The same thing happened when we put our 10 back together with the 450 detent spring.  On the stand it wouldn't shift up to third unless you put a little presure down first so the detent could engage the star. When we rode it   it never happened.  And after about five hours of riding it went away, or worked itself in.