Cant shift past neutral with sprocket cover installed?

Hello all. I just picked up a 93 xr650l to ride during my ducati monster's downtime. This bike is soooo much fun.

Anyways... When I bought it the front sprocket cover was not installed. Neither were the 2 bolts that secure it. After cleaning it up, I reinstalled the cover.

Today when I went to ride it a little, it would not shift into 2nd from 1st or neutral. No half engagement, no anything. If i pull up on the lever pretty hard, the neutral light will go out, but no 2nd gear.

While pushing the bike with the engine off, I can ease off of the clutch while pulling up on the gearshift lever and engage 2nd gear. From then I can ride it from 2nd-5th but when I shift to 1st, I am stuck with it or neutral.

I removed the sprocket cover and the problem goes away. I suspect interference with the top sprocket cover bolt, but I am not too familiar with this engine, so I don't know what the exact problem is.

Is this a common problem? I searched but didn't find anything similar.

Any suggestions?

Thanks.

Hello all. I just picked up a 93 xr650l to ride during my ducati monster's downtime. This bike is soooo much fun.

Anyways... When I bought it the front sprocket cover was not installed. Neither were the 2 bolts that secure it. After cleaning it up, I reinstalled the cover.

Today when I went to ride it a little, it would not shift into 2nd from 1st or neutral. No half engagement, no anything. If i pull up on the lever pretty hard, the neutral light will go out, but no 2nd gear.

While pushing the bike with the engine off, I can ease off of the clutch while pulling up on the gearshift lever and engage 2nd gear. From then I can ride it from 2nd-5th but when I shift to 1st, I am stuck with it or neutral.

I removed the sprocket cover and the problem goes away. I suspect interference with the top sprocket cover bolt, but I am not too familiar with this engine, so I don't know what the exact problem is.

Is this a common problem? I searched but didn't find anything similar.

Any suggestions?

Thanks.

Sounds like there is some interference with the shift lever and the sprocket cover. Is the shifter lever bent? Maybe near the shift shaft? Second gear can be a weak link on these engines, but it sounds like an external clearance issue.

I just went out and looked at mine... Unbolt the shift lever and drop it one or two teeth on the shaft. This should fix it.

Thanks for the reply. I just remembered that a .Haynes manual was included with the bike. I'm going to take a look in there and see if there is an exploded view of the engine.

I feel that the problem is internal. I checked for obvious external clearance issues. I can run with the cover on, but only without the top bolt. It's about 3" long and is also used to secure a clutch release pivot of some sort.

Hopefully it is a simple fix. I will read up on the manual and post back up.

Shorter bolt???? Just a thought.

Sorry for wasting your time. I'll blame it on the dark, or a moment of stupidity on my part.

Of course it was a bent shift lever that would hit the sprocket cover.

I couldn't see clearly last night when I checked it out, but this morning it was obvious that it was hitting the cover.

Maybe I'll have a real problem to ask advice about sometime.

Thanks again.

Try an MSR shift lever. They are very stout and dont bend easy. The stock lever is a limp noodle.

limp noodle LMAO good one!! Mine was rubbing from the last owner so i moved it out on the shaft, make sure yours isnt too close or it will wear pretty good. I gotta keep an eye on mine cuz its pretty tore up now.

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