JAMMED IN GEAR

stirlinggaz · World Chat Champion Joined: 22 Jul 2007 Karma :

hi all,
i've just had the crankcase cover off.(MTX 200)
(mainly to check on the bearing on the atac shaft)
& when its in bits, ie with no gear oil, the gear lever is loose & looks like its working properly. (it was before, but was a bit stiff to change gear).
but as soon as i refit the crankcase cover & re-fill with oil,
the gear lever is solid! it wont budge.
anyone any ideas?
im pretty sure i've not missed out anything but the gear lever feels like its jammed somewhere.
cheers,
GAZ

iooi · Super Spammer Joined: 14 Jan 2007 Karma :

When you say loose with the cover off. Just what do you mean ??? Does it change the gears....
Or just flop up and down.

Could be the shaft is seiezing on the bearing/seal in the crankcase.

How much oil you putting in.

Is the gear lever a simple lever of has it got a few rose joints in it.
____________________
Just because my bike was A DIVVY, does not mean i am......

stirlinggaz · World Chat Champion Joined: 22 Jul 2007 Karma :

hi,
the gear lever attaches straight to the shaft, so no fancy linkages or anything.
before i refitted the crankcase cover, the lever was moving a bit, as it usually does, but i didnt try & change gear.
then when i put the cover back on & re-filled it with oil, i noticed the gear lever was hanging down lower than normal & it was looser & wouldnt change gear.
so i started again.
& upon dis-assembly, it looked like the gear shift pin wasnt seated correctly.
i corrected this. (just pushed back into place) & again re-assembled.
this time, the lever is approx where it should be, but wont budge? wtf?
i must be missing something, but unfortunately the workshop manual is rather vague & the black & white pics are next to useless!
cheers,
GAZ

stirlinggaz · World Chat Champion Joined: 22 Jul 2007 Karma :

hi all,
my mtx wont change gear,
it was changing gear, but it was getting more & more difficult.
i removed the crankcase cover & it all looks ok, i think. (see pics)
when the cover is off, the gear lever can be moved, but it wont change gear,
when i put the crankcase on, the lever tightend up & wont even move!
anyone any ideas?
cheers,
GAZ

MaybeGuy · Super Spammer Joined: 12 Mar 2007 Karma :

looks like its 1 tooth out or something. slide it off and move it 1 tooth clockwise.
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Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

stirlinggaz · World Chat Champion Joined: 22 Jul 2007 Karma :

sumpgard · Nova Slayer Joined: 20 Nov 2008 Karma :

my mtx 125 does this every time i take the clutch cover off you have to push the lever out push it down against the bit with teeth then push it back in if you have tension on the gear lever it should be ok just check it before you put the case back on and make sure the shaft doesnt get moved.

frazer1981 · Nitrous Nuisance Joined: 04 Oct 2008 Karma :

Have you checked that you put that gear in place correctly? The teeth need to face into the engine, and not outwards as in your picture. The teeth on the gear need to engage on the teeth circled in my picture below.

https://i154.photobucket.com/albums/s241/VR_XRAY/Picture001-1.jpg

I last time i took my clutch cover off it took my ages to get that bloody thing to line up. Evil or Very Mad

The best way i found was to place the gear in there and with the bike on a stand put it in gear up and down though all gears to make sure it was ok. Do you have a workshop manual? Should show you in there?
____________________
1st bike - chunlan starway 50QF4 (SOLD) 2nd bike - 92 Honda mtx125RW-L ( In my garage awaiting some TLC)
05 Honda xl125v Varadero stolen and recovered but now a write off! Sad

07 Hyosung GTR125R

stirlinggaz · World Chat Champion Joined: 22 Jul 2007 Karma :

hi,
& thanks for the relies.
i thought it was something to do with lining it up.
problem was, when i removed the crankcase cover the little part with 2 rows of teeth fell out!
so wasnt 100% sure i had lined it up properly.
i do have the official workshop manual (hard copy if anyone wants a copy of t or i could try & get it scanned & uploaded on here?)
but the pics arnt up to much. being black & white.
im now off to give it another go,
cheers,
GAZ

stirlinggaz · World Chat Champion Joined: 22 Jul 2007 Karma :

stirlinggaz · World Chat Champion Joined: 22 Jul 2007 Karma :

DOH!
how thick am i?
the more i looked at it, the more i realised frazer1981 Thumbs Up

was right,.
the little footprint shaped gear thing was on back to front!
tuned around & it eventually changed down into 1st.
heres hop ing its all alright when its filled upwith gear oil.
thanks,
cheers,
GAZ

frazer1981 · Nitrous Nuisance Joined: 04 Oct 2008 Karma :

Once you get it all lined up correct, put the case on and try going though all the gears. I did it put it in 1st back to neutral and put everything back togther and it would'nt go in to 2nd Rolling Eyes

so had to pull it all apart again Sad

____________________
1st bike - chunlan starway 50QF4 (SOLD) 2nd bike - 92 Honda mtx125RW-L ( In my garage awaiting some TLC)
05 Honda xl125v Varadero stolen and recovered but now a write off! Sad

07 Hyosung GTR125R