ok guys
this is what i got it goes in to gear and wont come out with side cover on but if i take the cover off it will shift ok by hand none runing so what heck could it be it all looks good all seems to be working till you but the cover back on and shift it up 1 time and then nothing it is stuck in that gaer till you take the cover off
i have tried changing the oil and changing the ajustment on the out side cover nothing seems to work and i have been unable to find any kind of manule on line any help out here

o ye it is a 2001 exp 425 that i just got and no nothing about it othere than it runs good lol

 

Welcome to the forum! It could be as simple as a flange bushing galled up in the cover binding up the shifter or the internal release lever,or pressure against the shift detent on the the shift drum causing the problem. You really need a manual on this engine due to all the parts involved. Look here under your model on "clutches" to show what's involved. Browse
OPT

 

i have looked at it once agin and see nothing but i am thinking that when i put the cover on that some thing is moving in there that is causeing the shifter to be out of sink and that why it hangs up and wont shift out of grear
when i get home to day i am going to check this out

 

When you adjusted the clutch adjuster on the outside of the cover did you just turn it in until you felt pressure and then backed the adjuster out 1/8 turn and tightened the lock nut? Don't know if this might help or it's binding possibly in the shift drum detent (shift cam) area. OPT

 

ok i think i mite have it figered out the asm shift arm has 2 springs on it and i now have it acting up with the cover off and it seems to be that spring load arm is not going up and down like it should so i am taking the bike to work and taking it all apart tomorrw so if any one has worked on this i coued use any info i can get

 

These are the two shift springs on the shift shaft that allow it to grab the detent (shift cam) on the shift drum and then ratchet back to get another bite. Sounds like you've found the problem. OPT