81 GS250 stuck in neutral HELP

[Guest]

I'm a newb and I picked up a low mileage 81 250t in nice shape EXCEPT... a previous owner must have switched the clutch cover oil plug and the shift detent bolt driving the detent pin to be stuck in the case. I can not get it out. The shift drum doesn't even wobble.
Suggestions?

[tom203]

Not sure what you are blaming here... so stuck in neutral, does gear lever move? Have you pulled the clutch assembly to see if something is out of mesh?

http://www.alpha-sports.com/spst/1981%20GS450L/25.htm?q=suzuki-parts

[Gorminrider]

boy that's a hard one...I'd like to say a magnet would pull it out but that's pretty unlikely... maybe drilling a hole down into it and setting a stout screw in to wiggle it loose...

[John Park]

boy that's a hard one...I'd like to say a magnet would pull it out but that's pretty unlikely... maybe drilling a hole down into it and setting a stout screw in to wiggle it loose...

I'd think that it would be pretty hard metal. I was thinking maybe a tap screwed in like an easy out might budge it. It's possible that somebody left the plug out and water pooled in the hole and rusted it in. Heating the area good and hot would expand the case around it, but might be hard on the paint.

[Gorminrider]

..yes and to heck with the paint! ^ ^ Just the tap might be a good try...of course they are prone to break off when twisted into too small a pilot hole but so is a screw(bolt) so you'd have drill the pilot hole "largish" so that the tap goes in fairly easy but the shank of a tap is pretty tough ...and being down that hole, it'd be unlikely you could wiggle-and-pull it too much to snap it...

[John Park]

..yes and to heck with the paint! ^ ^ Just the tap might be a good try...of course they are prone to break off when twisted into too small a pilot hole but so is a screw(bolt) so you'd have drill the pilot hole "largish" so that the tap goes in fairly easy but the shank of a tap is pretty tough ...and being down that hole, it'd be unlikely you could wiggle-and-pull it too much to snap it...

I think the plunger is already hollow where the spring goes into it; it's been a while since I really looked at one. Maybe someone could check to see if is the same part as a 450 one and then pull one out to see what it is we're trying to extract. I'm busy with other wrenching today so; volunteers? This is the sort of job that could go sideways if you don't do the thinking first.

[Gorminrider]

OP must have got it fixed. I just noticed he started it in september! 10/08/2016. haha.ohwell.

[johnsoxer]

Sorry about reposting everyone. I never got notified of any responses.
I thought no one cared!
Still struggling.
If I have to pull the motor and split the cases, can I split the lower without removing the upper as the manual describes?

[Boba]

Sorry about reposting everyone. I never got notified of any responses.
I thought no one cared!
Still struggling.
If I have to pull the motor and split the cases, can I split the lower without removing the upper as the manual describes?

You have to go to your user settings and change how your subscriptions work and notifications. Otherwise, the default settings are to not subscribe you to your own threads automatically, or any thread you post in. And default is to send you not notification of thread updates.

[Gorminrider]

Hey,ok.You're back.
I'll take a picture of a plunger from a gsx400 today (same as your 250 I'd hope-they are very similar I think.).

Usually someone responds to these helpme posts pretty quick. Don't know how you got missed in september but it does happen...If Tom203 hadn't seen it...well anyways it doesn't hurt to bump your own thread with another post

[Gorminrider]

neutralDetente.jpg
in order...(big side up, then spring then hollow nut.
The magnet+nail shown at top to lift it out...changing gear from neutral lifts it a bit ....

[johnsoxer]

Yeah that's it but it's JAMMED in. Not loose at all and shift drum doesn't even wiggle.

[Gorminrider]

hmm.I was futzing around with the pin...I am not sure how it could get driven in so hard as yours is.. it looks like the wide top would be stopped pretty well by the Case itself...there's not really any how the pin could get "driven in" to it . so, I think possibly someone put a spring on the pin!? I know, it won't fit but some other spring maybe...?That'd jam it but good!

Any sign of a lot of corrosion? white powder? I guess you've tried to dump penetrating oil in (acetone+ATF is pretty good to try).and wiggling shift shaft with pliers
Not sure what a shift-drum is but Not a gearbox expert- I'll have to have a look at the parts diagram...