So I picked up a 2002 ds650 baja few days ago. owner tells me it's been sitting for the past 2 years.. And judging by what I found in the carb I believe him. So I got the bike tuned up and running good but the issue I'm having is it will not shift out of 1st gear when the bike is on. But with the bike off I can shift thru all the gears just fine. The clutch is maxed out on adjustment aswell. Another thing if I jack up the rear wheels and let them spin I'm able to shift in 1st (n) 2nd 3rd 4th 5th with the bike on. So any help will be greatly appreciated.

 

Sounds like a classic case of stuck clutch plates. I would have this happen every time
I let my YZ125 sit unused for any significant time.

Try this: jack up the rear and start it in gear. Shift to highest gear. Give it
some revs (not wide open), then pull the clutch in and step on the brakes.

If that does not break the clutch loose, you will have to open it up.

 

I just tried it still nothing I really hope it's not the shift forks. But every gear goes in butter smooth so idk. I really hope I just need a new clutch.

 

I had a 650 , hence the name Budman650, and put a Barnett clutch in it and had the same issue. It would shift but it took awhile to loosen up until it got warm.
A bent shift fork usually has the symptom of popping OUT of gear.
Maybe the po put in a new clutch and didn't stack it correctly or it might have a warped plate.

 

OK, JP, so you tried it jacked up in the air?

Try starting it in gear, then driving it. Pull in the clutch and try to
accellerate. Hard.

Be careful. That unit has gobs of power. I drove and worked on one 5 mo
ago.

Stuck plates does not mean you have to replace the clutch. Just free them
up.

 

Ohh Awesome I'll try that tommorow. This is my 5th ds650 and I've never encountered this issue. I'll keep you guys updated I'm gonna take her out for a spin see if it pops them loose.

 

I jacked it up in the air and put it in gear gave it maybe 1/4 throttle and hit the brakes a few times but still same issue. I'm gonna try taking it for a spin tommorow hopefully she breaks loose.

 

"Update"

I took the cover off and removed the clutch. The pressure plates where badly burned and warped in 4 spots and stuck to the clutch basket took me like 30 minutes to remove the first 3 pressure plates. So time for a new clutch and new clutch basket. Thanks again for all the help.

 

Sorry to hear that, JP. I have a Suzuki Samurai where the dry clutch plate and
friction disk were so stuck, it took a chisel to get them apart.

Some folks don't know how to adjust their wet clutches and burn them up. But, that
quad is really powerful, too.

Anyway, since you are willing to do the install, the cost should not be too bad.

 

I found a used clutch today for 50 bux today installed it and it now shifts. The old clutch was completely burnt and warped. But all is good with the world again thanks again for all the help.