TZR now a general gearbox question

[Timmeh]

'lo

So the gearbox has stopped working. I'm thinking at bent/worn dogs or something similar. Clutch isn't the issue, it'll happily disengage, however I cannot find any gear and the selector is jammed solid.

I know how to split the case having watched a handy DTR125 vid. I have the clutch puller tool which I also used to get the stator off, so I just bolt that to the case and wind it out on the crank.

As I'm only after the gearbox, can I get away with not dismantling the clutch side of the engine? Or do I have to rip both sides to bits before splitting the cases?

Cheers dears
Timmeh

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GSXR400 x2 | '94 RVF400 | '93 TZR125 4DL (again)
20:22:30 BLUEX5: i would love to be forced to undergo a**l plugging with different sizes
20:48:18 Temeluchus: comp you hunk of smouldering homos3x you

[weirdomagnet]

I think you will have to split the clutch side mate,i think there is a plate behind the clutch basket that has to screws/bolts that hold the two halves together so clutch needs to come out also the gear selector rod goes in from that side etc.i could be wrong but ive rebuilt/split lots of x7,ypvs,ts125 and lots of rd250lc,s and they all had the bplate behind the clutch basket.ive just stripped a fzr100 exup engine and that was the same mate.just double check with a Haynes manual or google just to be sure though.

[weirdomagnet]

my buttons are sticking on my keyboard so spelling might be wrong/missing letters !!

[SQL]

both sides need to be stripped detailed pics here

<secretplug> https://www.bikechatforums.com/viewtopic.php?t=276485&start=50 </secretplug>

https://i.imgur.com/OHlpXVL.jpg

https://i.imgur.com/miJOktf.jpg

https://i.imgur.com/kx0X8qD.jpg

https://i.imgur.com/rp3DNzJ.jpg

If you need any spares I am breaking a second engine/parts of it

[Timmeh]

1. bugger.

2. cheers on the bits offer, I'll let you know how fucked the gearbox is.


____________________
GSXR400 x2 | '94 RVF400 | '93 TZR125 4DL (again)
20:22:30 BLUEX5: i would love to be forced to undergo a**l plugging with different sizes
20:48:18 Temeluchus: comp you hunk of smouldering homos3x you

[Timmeh]

Well finally managed to get it apart after lots of faff and waiting for a mate to lend me his hub puller thing, and finding the time to do it.

I have a feeling this thing's been apart before as I noticed a couple of things;

1. Counterbalance shaft not quite in the right place
2. No gasket between L & R halves

The outcome of the gearbox issue is that the shift drum had jammed and one of the selector fork pegs had come adrift. Something's still not quite right with it though, so it might still have to come totally apart; for some reason the shift drum can move laterally and disengage from the gear lever shaft. At least it now spins and I can find 1-6 and N.

Bearings and crank seals look ok, I might just replace them anyway. Might as well do the bottom end now that I've got it in bits.

As for getting it back on, am I right in assuming that it's just the main bearing that's an interference fit? So presumably the plan of popping it out of the case, heating it up, sliding it back over the crank, allowing to cool, and then warming up the case would be the way forward to get it back together? I know that hammering the thing back on is totally not the thing to do.

Cheers dears

____________________
GSXR400 x2 | '94 RVF400 | '93 TZR125 4DL (again)
20:22:30 BLUEX5: i would love to be forced to undergo a**l plugging with different sizes
20:48:18 Temeluchus: comp you hunk of smouldering homos3x you

[Timmeh]

So I've popped the mains out so I can slide the cases together and check the gearbox over. I can find the gears, although sometimes it'll get stuck between gears. Turning the input shaft whilst moving the lever shaft seems to help and it'll pop into gear.

Is this normal? I'm a little bit out of my zone here. The box has always felt a little vague on this bike (true for both 4DL's I have owned tbh)

So I'd just like to know if it's ok to put it back together again.

Cheers
Tim

____________________
GSXR400 x2 | '94 RVF400 | '93 TZR125 4DL (again)
20:22:30 BLUEX5: i would love to be forced to undergo a**l plugging with different sizes
20:48:18 Temeluchus: comp you hunk of smouldering homos3x you

[Hugh Farking Cant]

Yes; the shafts need to rotate to enable smooth selection.
Some gears may be selected without rotation but not guaranteed.

From your previous post; there is no gasket between c/case halves ;
only a liquid compound.
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Remember; Someone on here always has a blacker cat.

[SQL]

Theres isn't a gasket between the halfs just a smear of clear instant gasket mate.

I had the same problem if you can select 1st without turning it much don't worry.

[Timmeh]

Awesome!

So that's all sorted then.

When I split the halves there wasn't any gasket of any sort, clear or whatever. Might explain why the bike was down a bit on power. Although it is also ludicrously downgeared so might put it back to 18T front as it runs out of oomph at 80mph.

Cheers guys


____________________
GSXR400 x2 | '94 RVF400 | '93 TZR125 4DL (again)
20:22:30 BLUEX5: i would love to be forced to undergo a**l plugging with different sizes
20:48:18 Temeluchus: comp you hunk of smouldering homos3x you