aussiechris Posted August 4, 2015 Report Share Posted August 4, 2015 No Cabby, the top hat is on the right (there is a line joining the green bits to the red bits in that diagram). Once you remove the clutch, you will see the top hat (red arrow below) which is held on with a circlip. After re-assembly, you have to adjust the eccentric bolt indicated with the green arrow below. You might want to consult the Jim Snell "GasGas Pro Engine repair videos" videos at http://www.trialspartsusa.com/youtube.htmlto see how that is done. Quote Link to comment Share on other sites More sharing options...
baldilocks Posted August 4, 2015 Report Share Posted August 4, 2015 (edited) On the later bikes you pull the bearing through from the clutch side then i think there is enough space for the shift shaft cams to pass through. Check before you start as its 2 years since i did this Edited August 4, 2015 by baldilocks Quote Link to comment Share on other sites More sharing options...
biffsgasgas Posted August 4, 2015 Report Share Posted August 4, 2015 I am slightly confused by that picture above. I need to remove the clutch to see if tophat is broken but seems the tophat is actually at the gear lever side, is that right ??? cause that's how it looks in that picture. No the top hat is on the clutch side. It connects to the opposite end of the shaft that the shift lever connects to. You can see the slot in the shaft that the pin that breaks slides into. I will try to video it tonight. --Biff Quote Link to comment Share on other sites More sharing options...
cbutler Posted August 4, 2015 Report Share Posted August 4, 2015 If you look at the line they just have it shifted to fit on the page it goes on the end of the shift shaft. Quote Link to comment Share on other sites More sharing options...
cabby Posted August 4, 2015 Author Report Share Posted August 4, 2015 OK, to let you know where I am at the moment. I have the clutch out, and have rocked the lever, when going up to second the spring goes all the way out, however, when trying to go up another gear it only goes half way up (hope that makes sense). Took a vid of it but now my phone is playing up and can't get it to upload. Plus I need to get circlip pliers to remove said spring as it's tight as hell and won't come off with the pliers I have at the moment. Anyway, is what I have described(poorly) still sound like the tophat issue ??? Quote Link to comment Share on other sites More sharing options...
biffsgasgas Posted August 4, 2015 Report Share Posted August 4, 2015 Yes because your not there yet. I did a really bad video but my boy Zippysgasgas hasn't told me the team password yet so we will do this with photos. Without the cir-clip and the washer under that clip removed you can't see the problem. Here is what the top hat looks like with the washer that would go under the cir-clip looks like. Now when you remove the clip and the washer you will see that the top hat shear pin is no longer one piece! Now my lesson is trying not to reproduce the failure that i am trying to describe each and every time!!! hahahah oh well. I didn't save the dab but i got props for trying. --Biff Quote Link to comment Share on other sites More sharing options...
cabby Posted August 4, 2015 Author Report Share Posted August 4, 2015 To be honest, that second photo shows me nothing as I can't see any difference, but that may be due to the poor quality picture. Quote Link to comment Share on other sites More sharing options...
michael_t Posted August 5, 2015 Report Share Posted August 5, 2015 When this happened to me I dropped it by the shop and had it fixed in no time... I used to love taking things apart and putting them back together but the easy stuff is relatively cheap for shops to do and they can do it while I am at work. Really I am just getting old and lazy but if it where me I would load it up and have the guys at the shop spend 30 minutes on it... I'm sure they would appreciate the fact that you got as far as you did. Quote Link to comment Share on other sites More sharing options...
michael_t Posted August 5, 2015 Report Share Posted August 5, 2015 (edited) If you really want to continue then... If you look closely at the picture the bar that goes from one side of the top hat to the other sits in the slot cut in the end of the shaft that it sits on. When the bar sheers off it still looks fine but it just turns in the top hat without turning the top hat ... at least that is what I think people are trying to say. Edited August 5, 2015 by michael_t Quote Link to comment Share on other sites More sharing options...
cabby Posted August 5, 2015 Author Report Share Posted August 5, 2015 Righty, have the top hat off and if you guys are referring to the piece that goes across the middle, then its seems fine to me. Quote Link to comment Share on other sites More sharing options...
aussiechris Posted August 6, 2015 Report Share Posted August 6, 2015 Hi Cabby, Yes that top hat looks ok. My suggestion is to put that back on and check the adjustment of the little eccentric post that the springs sit on. Check out the Jim Snell videos in particular this one https://www.youtube.com/watch?v=A80n7zq80n8 and go to time 6:28 to see this actual adjustment. That sets the center return point of the mechanism between each shift. If it's not right then the little cams in the shift drum won't drop into place for the next up-shift. Also, you need to have the chain on the bike and spin the rear wheel while shifting (and either slip the clutch on or put some resistance on the clutch shaft). This is because the dogs on the gears don't usually line up until things start turning at different speeds. Last time I had mine apart I was convinced it wouldn't shift the higher gears but once it was all together and I took it for a ride, it was shifting just fine. Testing on the bench is always difficult. Chris. Quote Link to comment Share on other sites More sharing options...
cabby Posted August 6, 2015 Author Report Share Posted August 6, 2015 OK, next problem then is, how the bloody hell do you get the thing back on and expect the spring to stay coiled ?? There seems no place for it to be retained ?? Also, the bold on the bottom left hand corner was removed and now has no thread to catch to go back in ??? Quote Link to comment Share on other sites More sharing options...
cabby Posted August 8, 2015 Author Report Share Posted August 8, 2015 Video Quote Link to comment Share on other sites More sharing options...
michael_t Posted August 9, 2015 Report Share Posted August 9, 2015 Not hearing the click - check the video from aussiechris above at 7:46... Quote Link to comment Share on other sites More sharing options...
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