Suzuki 2 Strokes

Hi
If any body out there can help in a niggling problem which has manifested itself on the bikes return to the road after being stuck in a garage since 1990.
I have a gear change issue which has me scratching for answers ,the problem is that when engaging any gear after 2nd going up the box it is difficult ,all gears coming down the box are no problem ,gear changing without clutch after 2nd are ok ,gear changing with engine stopped and on its center stand and wiggling the back wheel back and two I can engage all gears up and down the box .
The gearbox oil is clear of metal particles ,The gear change lever does seem to have too much play in neutral .
Any direction here would be helpful
Regards
Bazit

Possibilities that come to mind:

-clutch poorly adjusted or plates grabbing the clutch outer basket. Try the adjuster under the outer sprocket cover.
-gearchange pawl is wrongly engaged in the shift drum under the RH clutch cover. Easy to do if the clutch cover is off and you poke the shift lever. I found on my 550 I could not get above 2nd without huge difficulty, but down was easy...and it was that pawl out one tooth!

Good luck,
Mike

Hi
Any pics /diagrams as to correct pawl placement when in neutral.
Thanks

I cannot post pictures here and don't have time to upload to Photobucket and post link right now.

Rest assured its 'exactly central' when in the right engagement.

Someone may be able to post what that looks like!

Cheers,
Mike

I have that picture. I will post it when I find it. Will start looking now.

Ah yes. Here it is. This is a 550 but the 380 should be the same. The bike is in neutral. After looking at the picture and seeing the rusty clutch plates, this might be a 750. Still the same though.

Hi
Great pic of gear pawl ,and now a quick question relating to the spring behind the pawl my spring seems to have one part resting on the floor of the casing and the other under the pin ,is that how it should be ?as I cant see from your pic the whole set up,also is this position shown when the bikes in nuetral.
Thanks
Bazit

The spring 'fingers' on the pawl of the gear change shaft should lie either side of the pin. This is so whether pushed up or down, when released, the foot lever will centre again and so move that selector drum to where it needs to be to enable selection of the next gear ratio.

The good thing is, with the clutch cover off, you can mess about with it until its very easy to change right up and down, checking you need do nothing except maybe rotate the rear wheel a little to achieve that. If you can get to that state, you have it all correct and can button it up with confidence

Cheers,
Mike

Bike is in neutral. I stated that above the pawl picture.

The spring on the pawl is there to return the pawl to the center between shifts , if your spring isnt like shown it very well could be your problem .

Hi
Well all my problems are gone with regards to the gear change problems I have persevered with all your help and have now a running bike with all its gears ,yahoo I wonder what its going to throw at me next.
So thanks again for all those that posted helpful pics and guidance (maybe a 750 next).
Bazit
(Barry)