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benelli bn 125 2nd and 5th gear making a crunching noise

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777
Borekit Bruiser



Joined: 13 Jun 2019
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PostPosted: 17:51 - 17 Aug 2025    Post subject: benelli bn 125 2nd and 5th gear making a crunching noise Reply with quote
2nd gear went while going up a hill. cant use it at all, then 5th started making a bit of a crunching noise too. before i buy a new engine, any advice on what it might be?

im guessing its a tooth or two that have come off the primary or secondary cluster

i had a look at a schematic of the gearbox and it looks like 5th and 2nd gear are very close to each other, although i think theres a mistake in the schematic as they are diagonal to each other from the primary to secondary drive

https://www.easyparts.com/explodedview/Genuine-parts-Benelli-BN-125-EFI-4T-CBS-E4-2018-2020-Gear-box-m34213-d246983

Last edited by 777 on 18:41 - 17 Aug 2025; edited 4 times in total
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Easy-X
Super Spammer



Joined: 08 Mar 2019
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PostPosted: 18:25 - 17 Aug 2025    Post subject: Reply with quote
If it was me and a gear "disappeared" I'd be taking the engine out, splitting the case and ascertaining 100% what went wrong. But then, I don't need my bike as a daily.
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777
Borekit Bruiser



Joined: 13 Jun 2019
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PostPosted: 18:42 - 17 Aug 2025    Post subject: Reply with quote
Easy-X wrote:
If it was me and a gear "disappeared" I'd be taking the engine out, splitting the case and ascertaining 100% what went wrong. But then, I don't need my bike as a daily.


i will do after i fit a new engine
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Easy-X
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Joined: 08 Mar 2019
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PostPosted: 18:58 - 17 Aug 2025    Post subject: Reply with quote
777 wrote:
i will do after i fit a new engine


It's amazing how many connectors and pipes there are on even a basic 125 these days. Just take plenty of photos, you'll be fine Smile
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Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter
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