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Honda CB 250 RS Clutch issue dragging I think

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CMXCol:
Laverda Dave and McCabe

I will try both and get back with the results
I am beggining to think it may be a selector issue as I can push the bike in 2nd with the clutch pulled in there is a lttile resistance far more than in neutral but it's not too difficult to push.

CMXCol:
Update

The selecter drum see attached pic with gear selector cap in neutral position it appears to have a lot of play on it.
Clockwise or anticlockwise about 10 degrees i.e noise it makes a dunk dunk sort of noise, LOL
Clutch test on stand no dragging so it's likely not that.
I think the gear selector forks are either damaged or incorrectly fitted somehow or the drum is worn or possible a shaft bearing or the selector rings on the shaft it takes a bit of effort to get it to change gear fortunately I have some spares for these items and a main shaft in good condition so it's looking like I'll need to split the gearbox and check it out.
A few days work I'll post the results once I have got it split.

Skoti:
Good luck with the gear selector problem.

I've just had a close look at the photo, if that's silicone sealer visible please don't use it on your Honda engine because it's liable to block the oil feed passages to the camshaft and cause it to seize in the cylinder head, can also choke up the oil pump strainer gauze with predictable results.

Try to clean all traces of the stuff away when you split the engine, reassemble with new gaskets, spotlessly clean and dry gasket joint faces and you'll have a nice safe oil tight engine.



 

   

CMXCol:
Got the issue definitely gear box there are two problems shown red arrowed see attached image

1.The gear selector fork arrowed is not standard I have one off a spare shaft and that one looks like the one on the left not th eone arrowed the correct one.
2.The split ring is missing off the bearing I had to order one from CMSNL only place I could find one its a common classic honda part the 400/4 uses it as well

When I changed the selector fork and reassembled the gear change is smooth when I turn the drive shaft by hand and the shift selectorr shaft has little play clockwise or anti clockwise.
I also suspect this missing split ring may be affecting the clutch as this shaft has the clutch on it so any axial play even a small bit may have abn effect all that was holding this shaft in place was the clamping force of the two gearbox case halves.
Onc eI get the split ring I will rebuild it it'll take a few days from Holland.

Laverda Dave:
Whilst the engine is apart I strongly recommend you replace the balance chain because they do stretch and wear. A genuine Honda item is only available from CMSNL @£280+. A much better and stronger alternative is a DID go-kart racing chain available from £15 if you can find one as they are becoming pretty rare these days but try eBay. The chain is a DID 219HTM racing go-kart chain. You will need to shorten it to the correct length and mark the timing marks on it using dabs of white paint. The timing marks are set at O, 18 & 26 links.
If you can't find one contact the chain man, it used to be called Andy the Chain Man but Andy retired and his son runs it now. They always attend the Kempton Park Autojumble (on this weekend)..

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