f1ngerbang Posted April 27, 2014 Report Share Posted April 27, 2014 Hi all - apologise if this is in the wrong thread. I've got a 2004 GG 250 TXT Pro. I don't get out on it as much as I would like but the other day when I did I had an issue with selecting gears; it wouldn't go past second. Within an hour I ended up with only first and an inability to find neutral - day over. I got it home put it on the stand and it's as though it's jammed; there's no 'click' but the gear selector does move and returns so the spring is still functioning. A guy who I chatted to said it was the 'gear shaft selector' which are known to be an issue(?) and the only way to replace is by engine strip!!! In a weird way I'm happy to undertake the job (have an enduro rider / super mechanic for a good mate!) as I like to restore stuff but wanted to check if anyone else has had this type of issue and ask what they did to resolve it. If I need the shaft does anyone have a clue as to costs!? Any help greatly appreciated. Quote Link to comment Share on other sites More sharing options...
lineaway Posted April 27, 2014 Report Share Posted April 27, 2014 First you have to check the top hat. It is just the under the clutch. It is the only part that could cause the issue that you have with out the engine being split. Quote Link to comment Share on other sites More sharing options...
sectionone Posted April 28, 2014 Report Share Posted April 28, 2014 There should be two pinned posts added to the Gas Gas section: Clutch Rattle and Shifting Problems. The same questions seemed to get asked at least every couple of months. If it's not the top hat, the shift pawl broke and you have to split the cases and replace the whole shaft assembly. A cheap temporary way to fix the broken top hat is to remove the broken square metal bar and replace it. The steel reinforcing plate that comes with a door lockset has the perfect size square steel that can be cut and peened to secure. I've done it and it didn't cost me anything. Quote Link to comment Share on other sites More sharing options...
jse Posted April 28, 2014 Report Share Posted April 28, 2014 Hi all - apologise if this is in the wrong thread. I've got a 2004 GG 250 TXT Pro. I don't get out on it as much as I would like but the other day when I did I had an issue with selecting gears; it wouldn't go past second. Within an hour I ended up with only first and an inability to find neutral - day over. I got it home put it on the stand and it's as though it's jammed; there's no 'click' but the gear selector does move and returns so the spring is still functioning. A guy who I chatted to said it was the 'gear shaft selector' which are known to be an issue(?) and the only way to replace is by engine strip!!! In a weird way I'm happy to undertake the job (have an enduro rider / super mechanic for a good mate!) as I like to restore stuff but wanted to check if anyone else has had this type of issue and ask what they did to resolve it. If I need the shaft does anyone have a clue as to costs!? Any help greatly appreciated. Just to eliminate the possibility of a shift centering spring out of adjustment, you might want to check that first. The shift centering spring is under the clutch assembly. "Lay the bike on it's side to take the sidecover off and you won't have to change the oil and the rear wheel will be free. Loosen the 4mm capscrew up a little but not loose. Put the shift lever down into first but do not release it (you may have to rotate the rear wheel a little to get it to go into gear). SLOWLY allow the shift lever to come back to center and just before it hits center you should hear a light "click". If you don't, adjust the eccentric bushing (10mm open-end wrench) a very small amount either way and try it again (it only takes a very small amount of turning). Repeat this if necessary till you get the click. Then try the same process with shifting up into second gear, slowly allowing the lever to return to center to make sure you get the click. If you hear the click in first (downshift) and second (upshift) the shift shaft mechanism is centered, tighten the capscrew down (7-8 ft lbs, 10-12 Nm). It will usually take a few attempts to get it right, like adjusting four-stroke valves, but once you get the hang of it, it should be a lot easier. Usually I find that once I get it centered (hear click) on the downshift, it usually is centered on the upshift, but not always." Jon Quote Link to comment Share on other sites More sharing options...
f1ngerbang Posted April 28, 2014 Author Report Share Posted April 28, 2014 Thanks so much for the responses - I'll hopefully get out in the garage over the next few nights and let you know how I get on! Quote Link to comment Share on other sites More sharing options...
f1ngerbang Posted May 7, 2014 Author Report Share Posted May 7, 2014 Ok - so I removed the clutch plates (the outer had a metal filings type of 'paste' on it but other than that all clean and good) removed the basket and had a good old check - no issues to be found so engines got to come out. Considering the amount of work splitting the case and the little time I have available I think it's going to be best taking the engine out and have a professional complete the work - I can then put it back in the bike and enjoy it before the summers over! Could anyone recommend a mechanic / bike workshop in the Somerset (UK) area for this type of work? as close to Bridgwater would be good! Thanks in advance of any suggestions. Quote Link to comment Share on other sites More sharing options...
copemech Posted May 8, 2014 Report Share Posted May 8, 2014 If you do not have a local dealer/specialist, and you are willing to remove it, I would just put it in a box and post it to Gasser UK for a refresh. Love you long time! Do you r water pump seals as well. Quote Link to comment Share on other sites More sharing options...
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