Another Gear Box Conundrum for Y'All!!!

[DeuceBG]

Following on from my previous Thread, the reason behind my changing the Gear Box Oil was to try and address an Issue that's arisen over this past week.
After around 100 - 150 miles (seems to vary but never happens when the Engine is cold), the Box sticks in 2nd.
Take off from a Standing Start, into 2nd with no problems but then it refuses to move up another Gear without pulling in the Clutch, dropping back to 1st then trying again.
I've looked through various old Threads, (one of which advised removing, cleaning and lubricating the Gear Linkage which I have since done) but I can't find anything that describes the Issue I have.

Any thoughts fellow Tossers??

 

[DrFarkoff]

Did you grease and Clean the Gearbox lever pivot?

It sounds like the selector drum in the box is not "quite" returning to its rest position thereby enabling you to select the next gear

The only "thing" that can influence that is the Gear lever, linkage / Pivot

Try undoing the linkage from the lever and see if the lever drops freely?

If it doesn't move freely and fairly quickly downwards when released then thats the culprit

Or if out on road very gently nudge the lever down ever so slightly maybe just a couple of mill to click the selector drum the last tiny bit to its rest position so it can pick up the next cog

 

[DeuceBG]

Did you grease and Clean the Gearbox lever pivot?

It sounds like the selector drum in the box is not "quite" returning to its rest position thereby enabling you to select the next gear

The only "thing" that can influence that is the Gear lever, linkage / Pivot

Try undoing the linkage from the lever and see if the lever drops freely?

If it doesn't move freely and fairly quickly downwards when released then thats the culprit

Or if out on road very gently nudge the lever down ever so slightly maybe just a couple of mill to click the selector drum the last tiny bit to its rest position so it can pick up the next cog

I stripped the Foot Rest Mounting off, (along with the Double Rose Jointed Linkage), removed the Shift Lever from the Shaft then cleaned up and smeared with Copper Grease.
Everything external is definitely moving freely.

 

[DrFarkoff]

try the very gentle nudge on the lever down before you try for third

It "could" perhaps be a damaged selector fork or selector drum

One Hates to Ask, BUT have to ask but what Gear Oil have you in the gearbox ??

 

[DeuceBG]

SAE80w90 API GL-5.
Could it have become damaged through " Normal" Riding?
It's only just started doing this and I've had it for around 2.5 - 3k Miles now.


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[DeuceBG]

But.....I only put it in last night which was the first Oil Change I've done on the Box.
Not sure what was in it but the Local Dealer did a 36k Service on the Bike around 1500 miles ago so I would like to think they changed it and that they used the right Grade Oil.
It was very clean when I dropped it out.
That said, I thought a 36k Service also included the Rear Bevel Box Oil but they didn't do that!!


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[Ian J Hartley]

I stripped the Foot Rest Mounting off, (along with the Double Rose Jointed Linkage), removed the Shift Lever from the Shaft then cleaned up and smeared with Copper Grease.
Everything external is definitely moving freely.

Copper grease?!!? I think you mean Copper Ease?

Copper Ease is an anti seize compound and not a grease. If I was you, I would revisit the work you did using a proper water proof lubrication grease.

 

[DeuceBG]

Yes, Copper Ease.
Regardless of whether it the correct Lubricant for the Job, it's doing its Job currently and keeping everything free and moving.
It may be that a different, more resilient Lubricant is required for long term application but Copper Ease is all I have right now and is not the cause of my current Issue.


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[DrFarkoff]

GL5 was all I needed to see

Not usually but the drum gets a "burr" it can prevent the drum just clicking back to its central position

SAE80w90 API GL-5.
Could it have become damaged through " Normal" Riding?
It's only just started doing this and I've had it for around 2.5 - 3k Miles now.

 

[Steptoe]

I stripped the Foot Rest Mounting off, (along with the Double Rose Jointed Linkage), removed the Shift Lever from the Shaft then cleaned up and smeared with Copper Grease.
Everything external is definitely moving freely.

Did you push the gearlever insert/bush out of the lever ? It's the insert/bush that seizes in the lever and it's the insert/bush that the gearlever bolt holds in place allowing the lever to swing on the bush... so if the insert is seized in the lever the lever has very restricted movement when it's all bolted in place.

 

[DeuceBG]

Did you push the gearlever insert/bush out of the lever ? It's the insert/bush that seizes in the lever and it's the insert/bush that the gearlever bolt holds in place allowing the lever to swing on the bush... so if the insert is seized in the lever the lever has very restricted movement when it's all bolted in place.

I didn't do that.
I cleaned it all out and removed all of the Crud from both the inside Face of the Bush and the Face of the Shaft but I didn't remove the Bush from the Lever itself.
It looked to be in two parts, is this the case?
There appeared to be a Gap in the middle of two separate Bushes that seemed to have been inserted from either side of the Lever.
Back to work I go!!!
Thanks for that Mr S...

 

[Nin]

Yes two separate halves split longitudinally inside two other separate halves split horizontally - don't try and get them out.

 

[DeuceBG]

Yes two separate halves split longitudinally inside two other separate halves split horizontally - don't try and get them out.

Don't try to get the ones out that are split Horizontally?

 

[DeuceBG]

Don't try to get the ones out that are split Horizontally?

Ok, this what I have.
Calling Lever "Part A" and the Silver Bush "Part B", when B pushes thru A it's free enough when inserted from either side and as far as the centre.
If however it's inserted all the way thru Part A then it becomes quite tight, although greasing it does help.
Maybe some internal Corrosion to Part A is forcing the two Nylon Inserts out of shape but, if it is then it's not immediately obvious.
It's also odd that the Issue has only just manifested itself after nearly 3k miles.
What's everyone think?

 

[Nin]

Ah right that's different from mine I shall slink away quietly

 

[DeuceBG]

Ah right that's different from mine I shall slink away quietly

Thanks for your Input anyway

 

[DeuceBG]

Did you push the gearlever insert/bush out of the lever ?

Actually I was mistaken earlier, that's exactly what I did.
I've now done it again and refitted it using Grease instead of Copper Ease but I'm not sure that's going to make much difference to be honest.

 

[DrFarkoff]

Yup Use a sharp Knife or Hacksaw Blade to cut across the inner of the nylon bushes which reduces the pressure on them as a cylinder and allows you to peel them out

"Trying" Not to damage them too much i.e. Miss shapen?

Then just sandpaper or wire brush insert the corrosion out and apply rubber grease and reinsert the nylon bushes I always refit them with the cut at lower centre so that anything that does get in there can escape

 

[DeuceBG]

Yup Use a sharp Knife or Hacksaw Blade to cut across the inner of the nylon bushes which reduces the pressure on them as a cylinder and allows you to peel them out

"Trying" Not to damage them too much i.e. Miss shapen?

Then just sandpaper or wire brush insert the corrosion out and apply rubber grease and reinsert the nylon bushes I always refit them with the cut at lower centre so that anything that does get in there can escape

That's a Job for tomorrow then