Gas gas TXT 250 shifting gear box problem

[gasaxe]

New member. I wish I had found this form years ago.

 

I have a 2012 TXT 250 I ride near every day.

Went to town for milk and bread and when I tried to gear down to 3rd it would not click in.

I rode home in forth and drained the oil. It was clean.

Topped up the gear oil and went for a short ride.

3rd 2nd 1st now work but no 4th or 5th.

It's now parked. I'm in Central America. Parts are limited.

My son is going to California in a week and thought maybe he can get what I need to fix my gym on wheels.

This bike keeps this old man healthy and fit.

Any advice much appreciated.

I'm thinking this is the problem in the screenshot attached

[konrad]

Shaft Shaft MT280238043  https://trialssuperstore.com/products/gasgas-pro-gear-selector-shaft

But the shift drum may be damaged as well. 

Shift Drum MT280238031  https://trialssuperstore.com/products/gasgas-gear-selector-drum

I would disassemble and inspect prior to buying any parts. 

Trials Superstore is only one example vendor.  KTM dealers can also sell those parts.

[lineaway]

https://trialssuperstore.com/collections/engine/products/gasgas-shift-shaft-center-locator-and-spring

 This is the first part to check. that little thin piece of metal is designed to shear. The spring is included and zipped tied as it`s hard to install the spring. Its possible to weld this back together, just the spring is hard to deal with. Good luck, it`s probably one of these parts have failed. The top hat is the easiest to fix.

[gasaxe]

Hey guys thanks for your advice. I  will split the case before my son takes off and see if I can't get him to bring the parts home with him in mid November.

My summer starts soon and I want to be riding asap.

[arnoux]

Hey gasaxe

You DO NOT need to split the cases. You do not need to remove the engine. You can check, and fix,  this quite easily with just the removal of the clutch side cover and the clutch pack. Under the clutch pack you will see were the shift shaft comes right through into the clutch case. On the end of it you will find a top hat shaped piece and spring (see link below for image)

https://www.thehellteam.com/gearbox-selector-spring-assy

It is more than likely this is the only piece that will need replacing, but even if the shaft is damaged (less likely) from 2012 GG made the bikes so the shaft could be removed with the removal of a small retaining screw and washer, and the hole thing can be wiggled out the right hand side.

If you are stuck please feel free to PM or emaail me for help.

Paul. The Hell Team