Author Topic: 2019 V-Strom DL250 stuck in third gear  (Read 1305 times)

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Offline kwackboy

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #20 on: April 12, 2024, 20:53:38 »
Can I re-use the clutch gasket if I open her up?

My advice to you is get a mechanic to take a look ..
Chief trouble maker 🙂

Offline Brockett

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #21 on: April 12, 2024, 22:47:52 »
On another site a member asks for help with a back brake not working. Some well meaning replies offering solutions to possible problems were forthcoming. Me being a "big head" says "brakes need expert attention and not the well meaning guesswork as to the problem or possible solution". Not a well recieved POV. When someone reveals their lack of understanding about the innards of a motorcycle and asks for advice I think it is reckless to offer anything but "contact a qualified mechanic". Back in my young day we had less complicated machines that were all home serviceable to some degree and we had workshop manuals buyers handbooks, books and even magazine articles oozing information that enabled us to keep our bikes running. With no more than an exploded diagram of a BSA B33 engine clutch and gearbox I stripped and rebuilt the engine, new big end and main bearings rebore and piston, new valves springs and guides etc. Renewed the clutch and primary drive and was wise enough to not touch the gearbox with even the smallest spanner. The rebuilt bike ( with 16 inch rims laced to the hubs ) tugged a single seat sidecar around the country for four years until the stork delivered a baby to my wife and a car was bought. You know by now that I'm not clever and I was less clever back then but back then it could be done, unlike now. A cable operated drum brake was pretty simple compared to hydrualic disc brakes with ABS A magneto  with points and a carburettor was childs play compared to an ECU and fuel injectors. The only sensible advice for someone with little or no experience is "get a mechanic".
This doesn't last forever, so do it while you can.

Offline The Doctor 46

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #22 on: April 13, 2024, 00:43:04 »
Harsh but true Brockett. Very harsh.  :roll:  :thumb:
Without rain, there would be no rainbows.

Offline flyingcbf

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #23 on: April 13, 2024, 11:51:09 »
I've got it into NEUTRAL!!!


The gear lever now feels as though it's engaging. I've done nothing elese except pop pff the clutch cover...

I popped off the clutch cover, here it is....


The clutch lever in play...


but hang on!!!!
I've noticed some white residue...


Could the above be due to water and parafin that I used not long ago which might have crept in???
2019 Suzuki DL250, 2020 Honda CB125F

Offline Dark-Strom

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #24 on: April 13, 2024, 12:05:36 »
Not a mechanic (Dad was) but an engineer who services his own vehicles. Maybe the parrafin caused the clutch plates to stick together hence no clutch. Maybe dribble some oil between the plates with the clutch engaged. Then cover back on & put in some fresh 10/40 motorcycle oil and run for 5-10 minutes while moving the clutch in and out.  Then change the oil again and take it for a ride?  :shrug:
May your God go with you...
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Offline flyingcbf

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #25 on: April 13, 2024, 12:59:12 »
Unlikely as it will be stuck to one or both side of the case.

Thans for that! :ty:
The first link does not work.
The second one ebay: IS that compatible with my bike? I'm also looking at cuting out a gasket from a cereal box :)
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Offline flyingcbf

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #26 on: April 13, 2024, 13:04:37 »
Sorry I think I got that video about white residue wrong... Here it is:


2019 Suzuki DL250, 2020 Honda CB125F

Offline flyingcbf

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #27 on: April 13, 2024, 13:07:27 »
Not a mechanic (Dad was)

Yes I could try that with the cluthc engaged. It will make a big mess on the floor with no cover on though. But willing to try it with a cheaper oil
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Offline UK_Vstrom650

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #28 on: April 13, 2024, 13:25:17 »
Dark Strom did say put the cover back on before adding fresh oil...
Make sure you don't overfill the oil.

Edit: the white residue could be from paraffin if it got past the seals (I'm guessing you'd need to change the seals if that was the case), but it could possibly be emulsion from condensation if you've used it in winter for lots of short trips.

Offline Brockett

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #29 on: April 13, 2024, 13:26:03 »
With the engine off - Gears can be changed by rotating the rear wheel and moving the gear lever up or down lever. Nothing to do with the clutch.
This doesn't last forever, so do it while you can.

Online Rusty Nuts

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #30 on: April 13, 2024, 14:34:37 »
My advice to you is get a mechanic to take a look ..






This is a motorcycle mechanic offering his best advice, which is very much valued on here and presumably why you posted asking for help in the first place. Just sayin'...

Offline purplebikeunicorn

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #31 on: April 13, 2024, 17:03:00 »
Have someone else to help you, if you watch the gear selection mechanism (or perhaps record it) - you should be able to shift through the box by simply moving the rear wheel back / forth (the gears do not line up in the box, hence why you can't shift straight through from 1st to 5th, and also why you sometimes won't be able to change gears at a complete standstill).

You should see the selector mechanism return to centre after each change. Resist the urge to put your fingers in or near the change mechanism or the clutch basket, it will all spin.

At the very least, if taking to a garage isn't an option, if the mechanism now seems to work fine, and gears work, and the clutch appears to work, and we're thinking water in oil contamination, then button it back up, put some proper M/C 10w/40 (or other oil if specced for the DL250) in it with a new filter, run it through, and possibly consider changing the oil out again earlier than specified.

If you have any doubts about it (because if the gears get stuck again, you may get stranded!), I would get a shop to look at it.

Also: Never ever ever direct a pressure washer at any external seals on a bike (well, really any vehicle). They are designed primarily to stop the oil coming out, and low pressure water and crap getting in, so don't do a good job against 1000+psi water trying to get in. I use a pressure washer on my bike only for the final rinse from a distance. Front sprocket cover crap tends to be easier to brush off dry too ;-)

Offline Dark-Strom

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #32 on: April 13, 2024, 17:38:29 »
Purpleunicorn, that was my view, water underneath oil in the engine, I.e water in the gearbox / clutch hence not wanting to shift etc.
OTHERS - The OP had taken the matter into their own hands by taking the clutch cover off, so I was just trying to assist...
(Can't please everyone all the time)
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Offline flyingcbf

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #33 on: April 13, 2024, 20:37:56 »
I've cleaned the back of the clutch cover with brake cleaner and now looks good.
Question: Can I blast brake cleaner on the exposed engine parts?
2019 Suzuki DL250, 2020 Honda CB125F

Offline Valzdl650

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #34 on: April 14, 2024, 10:46:59 »
https://youtu.be/uuT0LUa_81c?si=xDX9IC9Komukb-_3

My issue is that when selecting first it doesn’t spring back however every other gear is fine , moving up and down it returns to the home position but in first there is a little lag I had the side opened and springs where good ? Maybe the issue is with the lever ??

Offline Brockett

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #35 on: April 14, 2024, 10:59:34 »
The spring has to lift the lever from first gear and it doesn't seem strong enough. For the other gears you are doing the lifting and gravity is helping the lever to return to the resting position.  Either the spring is weak or something is binding. It could be that the spring is broken. I would remove the lever and linkage leaving the end attached to the selector shaft and then repeat the experiment that is on the video
This doesn't last forever, so do it while you can.

Offline Valzdl650

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #36 on: April 14, 2024, 11:12:39 »
Yes so basically I was doing the steering barring so had the front up , I selected gear so back wheel would lock, at the same time I had the clutch cover removed so as I selected there was nothing for the rod to push against and it come off of the spring , I managed to get it back on the spring , at the same time inspected both springs and linkage and everything looked as it should so I don’t know what next step is

Offline Valzdl650

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #37 on: April 14, 2024, 11:16:40 »
Can’t upload the photos but in them you can see where it was not seated inside the spring and then once it was sitting correctly

Offline Valzdl650

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #38 on: April 14, 2024, 11:18:34 »
But yes both springs are good no wear , both in correct position , there is a bit of play in the gear changer maybe it could be this ????

Offline Valzdl650

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Re: 2019 V-Strom DL250 stuck in third gear
« Reply #39 on: April 14, 2024, 11:21:23 »
Before and after