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Netrual after engine rebuild is inbetween 3/4 gear :-(

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oddbod80
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Joined: 18 Nov 2010
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PostPosted: 21:21 - 11 Dec 2010    Post subject: Netrual after engine rebuild is inbetween 3/4 gear :-( Reply with quote
Evening everyone, hope your all ok.

I've got a question to ask if thats cool as i'm pullin me hair out here. I've just done a full engine rebuild on me 1985 suzuki 125cc ts125x and the problem i'm havin is when tryin to select the gears (engine on me bench) i'm gettin all 6 but the netrual is inbetween 3/4 gear and can't understand why?

I've had the engine completely build, twice to double check everythin and its still the same. (crankcase sealent on and everythin Sad )

I've set the selector cam as per the service manual i.e so the netrual dimple is visible from the oil drain plug hole but just can't get me head around why its doin this.

Now this is a daft question but does it need to be filled with oil 1st and have the cluth workin or is it somethin to do with the selector forks?

Thanks so much for your time and if you could help that would be spot on.

Steve.
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baldy
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Joined: 16 Feb 2004
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PostPosted: 03:51 - 12 Dec 2010    Post subject: Reply with quote
Have you put the little star shaped thing in the right way? The one on the end of the selector drum that has a little spring loaded arm hold it in place.

I once put it on upside down on a kmx125 and all sorts of wierd things were happening to neutral.

Other than that it may just be because it has no oil. Bike gearboxes like to be turning before they will go into gear properly. Or maybe you put the selector forks on the wrong way.

Do you still have the normal neutral?
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oddbod80
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Joined: 18 Nov 2010
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PostPosted: 10:54 - 12 Dec 2010    Post subject: Reply with quote
baldy wrote:
Have you put the little star shaped thing in the right way? The one on the end of the selector drum that has a little spring loaded arm hold it in place.

I once put it on upside down on a kmx125 and all sorts of wierd things were happening to neutral.

Other than that it may just be because it has no oil. Bike gearboxes like to be turning before they will go into gear properly. Or maybe you put the selector forks on the wrong way.

Do you still have the normal neutral?


Ay up baldy, cheers for the reply mate. (you was up late mukka Wink )

I'm sure i've put the cog the right way round but will double check that mate with the book as I no what way i've put it round. Now you come to mention it mukka I struggled to get the cam netrual needle lined up with the contact plate that fixes to the side of the case so I wondered if i've got it the wrong way round.

As for netrual being there in its correct place its not mate, just between 3/4th gear.

I'm goin to strip it down again in a minute on the kitchen table if me misses and kids allow me Wink

Thanks so much for givin me somethin to go off mukka your a star.

Will keep you updated.

Cheers mate,

Steve.
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oddbod80
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PostPosted: 18:41 - 12 Dec 2010    Post subject: Reply with quote
oddbod80 wrote:
baldy wrote:
Have you put the little star shaped thing in the right way? The one on the end of the selector drum that has a little spring loaded arm hold it in place.

I once put it on upside down on a kmx125 and all sorts of wierd things were happening to neutral.

Other than that it may just be because it has no oil. Bike gearboxes like to be turning before they will go into gear properly. Or maybe you put the selector forks on the wrong way.

Do you still have the normal neutral?


Ay up baldy, cheers for the reply mate. (you was up late mukka Wink )

I'm sure i've put the cog the right way round but will double check that mate with the book as I no what way i've put it round. Now you come to mention it mukka I struggled to get the cam netrual needle lined up with the contact plate that fixes to the side of the case so I wondered if i've got it the wrong way round.

As for netrual being there in its correct place its not mate, just between 3/4th gear.

I'm goin to strip it down again in a minute on the kitchen table if me misses and kids allow me Wink

Thanks so much for givin me somethin to go off mukka your a star.

Will keep you updated.

Cheers mate,

Steve.


Ay up Baldy,

Your a star mate!!!!

After readin your reply I stripped me motor back down and that star shaped cog was in correctly to the service manual but it is incorrect.

So I turned it round and there is a little notch that is where the spring loaded arm sits when its in netrual so BINGO it was in the wrong way round!!!!!! But the right way according to the manual so leason learned there.

I owe you one mate cause without your advice it would have ended up a push bike Wink

Thanks mate and have a beer on me Wink

Merry Christmas mukka,

Steve.
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baldy
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PostPosted: 22:17 - 12 Dec 2010    Post subject: Reply with quote
No worries, always glad to help.

I have just been made redundant again, so i have plenty of time on my hands. I worked the night shift so not yet got back in to the routine of sleeping in the night.
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oddbod80
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PostPosted: 22:47 - 12 Dec 2010    Post subject: Reply with quote
baldy wrote:
No worries, always glad to help.

I have just been made redundant again, so i have plenty of time on my hands. I worked the night shift so not yet got back in to the routine of sleeping in the night.


Thats s**t mate, sorry to here that pal.

You got anythin in the pipeline? Hope somethin turns up mukka.

Thanks again for the advice mate.
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baldy
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PostPosted: 23:42 - 12 Dec 2010    Post subject: Reply with quote
Got some money saved so having a break. After x mas i will go back to forklift driving.

Still getting a nice shiny KTM 400 EXC in three days.
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truslack
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PostPosted: 23:58 - 12 Dec 2010    Post subject: Reply with quote
baldy wrote:

Still getting a nice shiny KTM 400 EXC in three days.


Gimme a go Mister!!

Pleeease!!
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baldy
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PostPosted: 00:18 - 13 Dec 2010    Post subject: Reply with quote
If you come off roading one day i will.
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oddbod80
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PostPosted: 11:37 - 13 Dec 2010    Post subject: Reply with quote
baldy wrote:
Got some money saved so having a break. After x mas i will go back to forklift driving.

Still getting a nice shiny KTM 400 EXC in three days.


Haha thats class son!!!!

That knocks spots off my little ts125x but i've never rode a bike with gears before so thought i'd start off at the bottom and work me way up (bike virgin)

Brought it as a no runner 3 years ago and the engines been in bit on the table since then so thought it was time I got it runnin (hopefully) so a full engine rebuild later and the squish height set to 0.7mm i'm almost ready to get it started and can't wait.

A bit of off road fun me thinks.

If you ever see someone on a red ts mate come and say hello and if its me i'll get you that beer I owe you.
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