moochy Posted January 5, 2014 Report Share Posted January 5, 2014 Hi, just been saying how reliable my 04 txt pro has been since I got it earlier in the year then the dreaded kiss of death strikes, came off my bike today and bike landed on left side, after crash lever seemed to stay down after selecting down a gear ant up after selecting up a gear not returning to original position, as I am new to trials I have not experienced this before, and my mechanical skills are minimal, is this a big job to rectify and is it possible to try my self, many thanks ? Quote Link to comment Share on other sites More sharing options...
lineaway Posted January 5, 2014 Report Share Posted January 5, 2014 You can pray that it is the top hat and return spring. 10$ in parts and about an hour work. Which requires the clutch basket to be removed. With the shifter not returning, it could be a broken shift shaft assembly. That requires a whole engine tear down. Quote Link to comment Share on other sites More sharing options...
thats_a_five Posted January 6, 2014 Report Share Posted January 6, 2014 Before you tear into the cases, check the easy things first. Is the shift lever dragging on the left engine case? If not, check the shift mechanism inside the clutch housing. Search Youtube for the Jim Snell GasGas videos. He has one all about proper adjustment of the mechanism. This will give you a great visual of what the shifter mechanism is and how it should work. You can decide if that is within your skills to fix yourself. Good luck. And yes, we all crash from time to time. Quote Link to comment Share on other sites More sharing options...
moochy Posted January 6, 2014 Author Report Share Posted January 6, 2014 Thanks for the reply guys, I'm hoping its the top hat and return spring then as a engine tear down is out of my capabilities I would presume, the lever is clear of the casing and I can still change gear although not all that smoothly, I will check Jim snells video and take things from there, many thanks again guys Quote Link to comment Share on other sites More sharing options...
moochy Posted January 9, 2014 Author Report Share Posted January 9, 2014 Hi watched Jim snells video and took clutch cover off and checked spring and top hat everything seemed to look ok ie nothing snapped off, what are the other possibilities this could be thanks Quote Link to comment Share on other sites More sharing options...
lineaway Posted January 9, 2014 Report Share Posted January 9, 2014 Both ends of the spring is there? Most of the time you cannot tell the top hat is broke without removing it. It breaks were the small piece sits at the end of the shift shaft. Did you try the shifter while looking at it closely? Myself I would pull it off and try the shifter without it. Be careful of that spring. Safety classes and all. The correct thing to do is zip tie the ends of the springs together and the spring slides off with the top hat. Quote Link to comment Share on other sites More sharing options...
thats_a_five Posted January 10, 2014 Report Share Posted January 10, 2014 (edited) You might want to pull the shift shaft (the one the foot lever attaches to) out and see if it is straight. Buddy of mine bent his in a crash. Bike would shift, but not right, and would pop out of second gear into neutral. Once we found it, a couple thumps with my 2 pound persuader and it was all better. Material was not heat treated so it bent back and didn't break. Let us know how you get on. ***Edit 1-10-2014. Please see correction from Lineaway that follows. This info applies to non-"Pro" models. Thanks. Edited January 10, 2014 by thats_a_five Quote Link to comment Share on other sites More sharing options...
lineaway Posted January 10, 2014 Report Share Posted January 10, 2014 (edited) That`s a five, the Pro motor does not work that way! If you have never worked on a Pro motor, it is totally different!! The motor has to be split on the Pro for the shift shaft to be removed. Edited January 10, 2014 by lineaway Quote Link to comment Share on other sites More sharing options...
thats_a_five Posted January 10, 2014 Report Share Posted January 10, 2014 That`s a five, the Pro motor does not work that way! If you have never worked on a Pro motor, it is totally different!! The motor has to be split on the Pro for the shift shaft to be removed. Thanks for the correction Lineaway. My frame of reference was the non-Pro "edition" models. 1 Quote Link to comment Share on other sites More sharing options...
dadof2 Posted January 10, 2014 Report Share Posted January 10, 2014 Unfortunately its a fair bet that you have bent the shaft or kinked the selector "pawl" mechanism both of which probably mean splitting the cases. It the lever feels as if its sticky and rubbing try to see if its bent and slip a bit of tube on to bend it straight. If the shaft moves freely but the gears don't select easily, it is likely the "chain link" types pawls are kinked. If you are running on automatic transmission fluid, try switching to 10W-40 or light 75-80 gear oil. It may improve after a few hour riding. Also check that the little piece of square section metal in the end of the top hat is not kinked or partially sheared. Quote Link to comment Share on other sites More sharing options...
sting32 Posted January 14, 2014 Report Share Posted January 14, 2014 My son broke the "safety fuseable part" described before that is on the very end of the shift shaft, behind the clutch, on his 06 pro years back. when this happened, the shaft would stay where ever you pushed it, but what was funky was you could shift the bike with a quick jab of the pedal/lever. it seemed that that fusable link was tight enough on the shaft, and where it broke would almost catch good enough to shift, occasionally though... But not good enough to return the shifter to "center" which at 1st baffled me, I was afraid that more stuff was ruined until I fixed it with the $15 fusable link part... I took the cover off, cluch out, pulled that part off the shaft off, it came off in 2 pieces as it should have, and put new on on, all was good. The red arrow points to the part we broke. In the center (visible in drawing) is the little breakable center pin like metal piece. His stayed in place, and like I said broke with enough jaggyness that it tried to shift due to diggin in and friction I guess. You can check that part really easily, by moving the lever. My guess though is, we could rotate the shifter 360 degrees, if you cannot, then you might have broken something past that (as inside the gearbox at the drum (Parts outlined as part#28 is inside the cases, and part #13 gets damaged when it failed to break the part I'm pointing to... 1 Quote Link to comment Share on other sites More sharing options...
dadof2 Posted January 17, 2014 Report Share Posted January 17, 2014 Thanks for illustration My guess is the bit across the inside end of the of the cylinder where the arrow points or the parts numbered 13 are kinked. Quote Link to comment Share on other sites More sharing options...
eddie1 Posted August 13, 2014 Report Share Posted August 13, 2014 My son broke the "safety fuseable part" described before that is on the very end of the shift shaft, behind the clutch, on his 06 pro years back. when this happened, the shaft would stay where ever you pushed it, but what was funky was you could shift the bike with a quick jab of the pedal/lever. it seemed that that fusable link was tight enough on the shaft, and where it broke would almost catch good enough to shift, occasionally though... But not good enough to return the shifter to "center" which at 1st baffled me, I was afraid that more stuff was ruined until I fixed it with the $15 fusable link part... I took the cover off, cluch out, pulled that part off the shaft off, it came off in 2 pieces as it should have, and put new on on, all was good. The red arrow points to the part we broke. In the center (visible in drawing) is the little breakable center pin like metal piece. His stayed in place, and like I said broke with enough jaggyness that it tried to shift due to diggin in and friction I guess. You can check that part really easily, by moving the lever. My guess though is, we could rotate the shifter 360 degrees, if you cannot, then you might have broken something past that (as inside the gearbox at the drum (Parts outlined as part#28 is inside the cases, and part #13 gets damaged when it failed to break the part I'm pointing to... Thanks your answer has saved me a load of work. I've just rebuilt the engine and it has been fine for the first couple of short rides then the gear leaver starts to stop returning and yes could be rotated 360 deg. A quick search on this forum bought up your answer. My first thoughts had been to just rip the engine back out and tear it down again. Clutch cover off , clutch out, all looked ok but the spring was not moving, clip off and it was not until I pulled the top hat out that I saw it had broken. Phew ,,,, Quote Link to comment Share on other sites More sharing options...
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