Hello I'm new to the forum, but need help. I have a 2001 xpedition 325, I broke the machine down to have the crank turned, new rod bearings and bored the cylinder + new piston. Put everything back together and cant get it into neutral. I have it lifted on jacks and the motor will turn over with the manual pull start and the back wheels turn every time. Any help would be greatly appreciated. Also it seems if I hold the shifter up or down I can force the gears to turn by rolling the tires. Thanking you in advance.

 

First place I'd recheck is the shift shaft,return spring,shift cam along with the cam stopper arm.Sounds like it's not ratcheting right. #25,30,33. Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Item #5 on the shift cam.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

opt,
I removed the clutches and the shift cam is in the neutral position, but I still cant move the wheels freely without hitting some gears. I can move the shift cam from neutral to 2nd and back, no 1st, 3rd, 4th, or 5th. Could it be in the reverse. I am assuming that I should be able to shift through the gears at this point. Thanks again.

 

On this you're going to have to recheck the shift forks to make sure you don't have one wrong in the shift drum notch along with the slider gears,etc. Somethings definitely not right if the shift cam is in neutral and and can't fully shift through the gears and back.Plus possible the reverse arm or spring isn't right causing the problem.Just retrace your steps.

 

OPT,

Just a follow up on this. I hope that if nothing more it will remind you of a time when you said or heard these words, "A round peg wont fit in a square hole and vise versa." In this overhaul I replaced all the bearings, time passed as the crank was turned and cylinder bored and I forgot that I even took the trans gear off when i changed the bearings, but apparently in an attempt to explore I flipped a gear. Running better than ever. Thanks again for your wisdom and advise to retrace my steps. Thanks Again!!

 

Glad it was something simple. I've done the same thing in not paying attention to how gears came out and have had to back track my work.

 

Russell,
I know your post was from a long time ago, but I currently have the clutches off my 425. To my knowledge the case has not been separated, but I too cannot get the shift cam to go past first gear. Def have neutral and first but won't go past that. Any ideas would be appreciated, thanks