Gear Shifter Problem On 06 Pro

[jandyb]

Hi

My brothers 06 125 Pro has a "problem" with the gear shifter. When in 1`st the shifter is supposed to stop but it is still possible to press it downwards. How is that possible?

He has tried to adjust the shift shaft center locator under the clutch basket, but it did not help.

Other than that this problem is irritating the gears are functioning quite OK. No problem shifting any gears.

Thanks for any help.

-Jan

[peterb]

Hi Jan,

Problem is very likely to be the 2 piece "top hat" gear selector spring retainer at the clutch end of ther gear selector shaft. The "top hat" - looks like a sleeve with a pressed-on washer at one end that incorporates a tab for the selector spring to hook over, has a cross piece fixed inside the ID of the sleeve, this cross piece locates into the end of the selector shaft, the tab part of the washer should be in the same plane as the cross piece - very hard to describe properly! What can happen is that the pressed on (may be brazed too) washer can slip around the sleeve which will give you the sensation of the gear lever having extended travel, as one of my bikes did a few years back.

Have a look, if the 2 parts are not lined up then best to fit a new top hat with spring. You can braze up the 2 pieces after very careful alignment though after doing this, if you strike a rock with your gear lever, the top hat will not have any give and you stand to break something more expensive in the gearbox!

Bye, PeterB.

[jandyb]

Hi Jan,

Problem is very likely to be the 2 piece "top hat" gear selector spring retainer at the clutch end of ther gear selector shaft. The "top hat" - looks like a sleeve with a pressed-on washer at one end that incorporates a tab for the selector spring to hook over, has a cross piece fixed inside the ID of the sleeve, this cross piece locates into the end of the selector shaft, the tab part of the washer should be in the same plane as the cross piece - very hard to describe properly! What can happen is that the pressed on (may be brazed too) washer can slip around the sleeve which will give you the sensation of the gear lever having extended travel, as one of my bikes did a few years back.

Have a look, if the 2 parts are not lined up then best to fit a new top hat with spring. You can braze up the 2 pieces after very careful alignment though after doing this, if you strike a rock with your gear lever, the top hat will not have any give and you stand to break something more expensive in the gearbox!

Bye, PeterB.

Thanks Peter

I think I understand what You mean, but I don`t think tis is the issue this time. As I said the gear lever is operating normally except when in first gear when it is possible to push it down like if there was another gear downwards.

I had a gearbox open last year and remember that I studied how this works then, but I cant remember what it is that stops the lever from going down when in first gear.

After a study of the exploded view in the part list I come to two possibilities: Either the "pins" on the gear forks that is following the guides on the gear drum or the two "ratchet rollers" inside the gear drum?

As I also said is the gearbox functioning normal except from this issue. The fault was there even when we bought the bike about a year ago and has not got worse so it is probably nothing to worry about. The bike is driven by my brothers daughter - hmm.. my niese - and as she have never driven other bikes she does not complain. It is just irritating when others are riding it..

[peterb]

Hi Jan,

Best way to see what is happening is to remove the clutch (centre bolt - do not use a ball end allen key, but a squared off allen key, tap the nut with a drift first), put it into first gear then move the gear lever past the normal point and see if the "top hat" at the other end of the gear shaft is slipping between it's two parts.

If not, then it is something more sinister, maybe a piece has broken from the shift drum wall or as you say, perhaps one of the pawls may have a problem, possibly a weak return spring (they look like a hairpin spring)

Bye, PeterB.