Motorcycle Repair: gear jumps, honda motorcycl, retainer plate


Question
Hi there, I have a 1991 250 Nighthawk, that does not stay in nutral I can shift it into neuatral, but it wants to jump to gear all the time. and when this happens the bike instals, to be able to restart it I have to rock the bike back and forth, then I can click the shifter into neutral and will start, and will do the same. any help direction will be highly appreciated.

Answer
Shaunt, The shift drum controls the selection of gears and there are several components associated with it. You didn't mention the mileage on the machine, so I don't know if it is a factor of wear or if something has come loose inside.
In any case the clutch cover will have to be removed after you drain the oil. Buy a new gasket and perhaps the seal for the clutch release arm before you dive in. DO NOT try to get by with the use of silicone seal instead of buying a new gasket.
The shift drum components are usually located behind the clutch assembly, so you may or may not be able to see them and do any repairs w/o removal of the clutch assy.
There is an odd sized 16mm lock nut holding the clutch to the input shaft, which may be a challenge w/o air tools and/or special tool to hold the clutch assy.

The end of the shift shaft has a bolt that holds the shift pin retainer plate. Be sure that it is tight. The other part the keeps the gear shift drum from over rotating is the shift drum stopper. There is a little roller on the end that can wear out or the retention bolt may have backed out causing it to jump out of position. Either return the stopper back into position with the spring and bolt or replace it if it has been damaged or is worn excessively.
If all of these parts seem okay, then I would guess that the problem is with the shift drum, which is a major engine teardown to repair.
You can get manuals from a local m/c shop, www.helminc.com
or Ebay, perhaps.
You can get a look at the parts on exploded views at:
http://www.powersportspro.com/partsfish/login.asp
Register and the select the HONDA motorcycle option, scroll down to the NIGHTHAWK 250 and then select GEARSHIFT DRUM option as well as CLUTCH and RIGHT CRANKCASE COVER.

Bill Silver