Gear Shifting Very Difficult

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

I use cereal packet all the time for gaskets. Alpen boxes seem particularly good, I always save these.

Proper gasket paper is also cheap. Amazon do flexoid gasket paper in a variety of thicknesses. I don't know how thick yours is, you'd probably need to measure the old one with a vernier/micrometer. That said, the thickness isn't all that critical on a japanese bike clutch cover because there aren't any spaced/shimmed clearances running in it. It's more critical on things like vertically split crankcase halves or gearboxes, or anything where a shaft of some sort is running between the two surfaces you are sealing.

The other (more traditional) way of taking the impression is to lay the paper over the surface and gently tap round the edge with a small hammer which will put creases in the paper where the edges are.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

Workshop manuals will usually tell you if there's a bit you need sealant on, it usually isn't the whole gasket. Most often where a rubber grommet goes through the joint. I sometimes grease them, sometimes don't. I'm not convinced it makes much difference other than allowing it to come off cleanly on future dissasembly. An odd thin smear of grease can be useful to hold it in place. Grease is engineers glue.

Don't believe everything you hear on Delboys Garage. He can be a bit redneck at times.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

jeffyjeff · World Chat Champion Joined: 02 May 2020 Karma :

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

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....
https://youtu.be/ZdH-a7Cbj60

The clutch lever in play...
https://youtu.be/IUZDudwhAdc

but hang on!!!!
I've noticed some white residue...
https://youtu.be/kttaS_AzGRM

Could the above be due to water and parafin that I used not long ago which might have crept in???
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2019 Suzuki V-Strom 250
2020 Cb125F @ 5k miles and going up!

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

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?
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2019 Suzuki V-Strom 250
2020 Cb125F @ 5k miles and going up!

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

That residue was probably just condensation, it's very light.

I can't think why taking that cover off would have freed up the gearshift but a win is a win.

Has the bike been ridden recently? When you pull the clutch, the stack is moving but not seperating very convincingly. It might be worth taking all the plates out and putting them back in again in case they are stuck together.

You can clean engine componants with brake cleaner, it all evaporates anyway. That said, it all looks very clean in there. The clutch looks in good nick too.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

The bike has been stationary for two-three weeks now due to the gear issue.
I can certainly have a go at taking those plates out but as an extra step, I could blast some brake cleaner at those plates? Then soak them in engine oil overnight?
My only concern is the torque settings for the clutch system, it's nowhere to be found on the net. Thumbs Up

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2019 Suzuki V-Strom 250
2020 Cb125F @ 5k miles and going up!

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

The weather has been so terrible still waiting to get out there and get some further work done. Thumbs Up

Question: Which oil would you put in your 4 stroke bike and why?
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2019 Suzuki V-Strom 250
2020 Cb125F @ 5k miles and going up!

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

DaddyStu · Spanner Monkey Joined: 19 Jan 2023 Karma :

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

So I've gone ahead and created a gasket from think paper. Similar thickness to cereal packet Very Happy

I've used normal bearing grease to use as stencil.
Waiting for the gasket seal to dry. It does say 24 hours to fully cure before filling her up with oil

https://youtu.be/z6nngORIbu4

Thumbs Up

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2019 Suzuki V-Strom 250
2020 Cb125F @ 5k miles and going up!

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

OK, so today I've gone ahead and filled her up with new oil and oil filter. I was really worried that it may leak from somewhere but so far no leaks detected. I took her out for a spin and made sure I used all 6 gears and brought her up to temperature. So far so good.
I took her out again and brought up to temperate using all six gears. Brough her back and cracked open the sump plug and oil filter. All oil drained out.
Then re-filled new engine oil and oil filter. Thumbs Up

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2019 Suzuki V-Strom 250
2020 Cb125F @ 5k miles and going up!

Nobby the Bastard · Harley Gaydar Joined: 16 Aug 2013 Karma :

What a waste of oil.
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050

DaddyStu · Spanner Monkey Joined: 19 Jan 2023 Karma :

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

I'm not sure if you read the whole post but it would appear that the engine oil might have got contaminated. Hence the need to flush it out.
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2019 Suzuki V-Strom 250
2020 Cb125F @ 5k miles and going up!

A100man · World Chat Champion Joined: 19 Aug 2013 Karma :

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

Ok, So I've booked the bike for an MOT later today.
Ive driven it out again and noticed that after about 20 mins of riding, the gear shifting seems to have become a little stiff again. It started out butter smooth so not sure what gives? Sad

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2019 Suzuki V-Strom 250
2020 Cb125F @ 5k miles and going up!

flyingcbf · Borekit Bruiser Joined: 23 Aug 2021 Karma :

Hi Chaps,
So any suggestion as to where to look? I came into work today and the gears shifting was super smooth but only for the first 15-20 mins. After that, gear shifting became stiff and difficult (hard) to shift into.

Clutch Friction Plates???
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2019 Suzuki V-Strom 250
2020 Cb125F @ 5k miles and going up!