muddytires Posted January 30, 2007 Report Share Posted January 30, 2007 (edited) Here's my dilema. I rebuilt my tlr200 back in the summer from a non runner. At first i was having trouble shifting through the gears. The lever would bind and had to forcefully knock it into gear. After riding a few times the shifting has become easier, like it should be. Strange thing is i have dropped it on the rear brake side a couple of times ( not hard, i,ve caught it so it wouldn't do damage.) Then it go's back to where its hard to get it in gear again. It loosens up after a quite a while of riding. Its got me baffled. The star shaped cam is in good shape and the shift drums seem ok. I havent dropped it on the gear shifter side, so i haven't bent that. I was wondering if this has happened to anyone else? Why would the gears be hard to engage after being on its side? I know the obvious answer would be not to drop it! Edited January 30, 2007 by muddytires Quote Link to comment Share on other sites More sharing options...
g4321 Posted January 30, 2007 Report Share Posted January 30, 2007 It loosens up after a quite a while of riding. Its got me baffled. Sounds like its easy to change when hot - cases have expanded? I had the same problem with one of my 250's - I suspected it was due to the cases being tight on the gear clusters - I welded a minor crack on the cases and lapped cases flat to ensure a good seal (virtually nothing was removed), this in conjunction with an aftermarket gasket made the cases tight on the gear clusters. Not a major problem, just I could not change gear in sections. I stripped motor and checked EVERYTHING again - I knew I had put box back together properly and there was no wear on selectors & selectors were true (not bent). I built up box in cases without remainder of engine(no crank etc) and tried various gasket thicknesses - et voila Next time you strip motor check all shims are in right place and there is sufficient 'free play' in the gear clusters. If an aftermarket gasket was used this may have been too thin? Strip motor, check everything and try a wider gasket (or even slackening off case screws when on bench with only box in cases) If you find the same problem as I did its easy to cure. Quote Link to comment Share on other sites More sharing options...
muddytires Posted January 30, 2007 Author Report Share Posted January 30, 2007 Thanks, i'll try that. I though maybe it was the opposite, and there was too much freeplay somewhere, causing something to slide out of place slightly when on its side. I suppose i'll have to take the case off again and check. Quote Link to comment Share on other sites More sharing options...
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