Gearbox fault developing?

[Taipan]

Hi All

Had a weird experiance on my Rockster tonight. I was riding home in traffic as I slowed for a red light the bike wouldn't change down through the gearbox. It was stuck in 3rd? As luck would have it the lights changed so I was able to keep going. I tried changing up and it went up the box ok and then I was able to change down through the box ok????

Thinking about it, a couple of times lately I have had trouble putting it into 1st. If I let the clutch back out an dtry again it always goes in ok.

Is this some sort of gearbox fault dedveloping? What is likely to be wrong with it?

Many thanks.

 

[littleredrooster]

Bollox - I've just answered this on visordown for you. I ain't typing it again!!!

 

[damo the onion]

Bollox - I've just answered this on visordown for you. I ain't typing it again!!!

yeah but nobody pays any mind over there, it'll be off the page in 2seconds replaced by some blather about somebody's new socks......

 

[Taipan]

Bollox - I've just answered this on visordown for you. I ain't typing it again!!!

Tsk ,lazy or what!

Thanks it was reassuring and from what I can gather elsewhere quite common too, especially if you try to change down multiple gears with the clutch held in?

 

[Taipan]

The problem has got worse and worse. As littleredrooster said it is indeed the linkage getting sticky. I cleaned the little ball joints as a matter of course, but its actually the foot lever. If I take the adjust rod assembly off the gearlever doesn't even drop. It just stays where ever you put it. So I need to get that off and clean it up.

Anyone know what inside there? Is it just a greased metal sleeve and the grease has juts turned to porridge? Or is there some sort of nylon bushing I need to replace?

Many thanks.

 

[(RIP) Kaister]

Glad to see its gone from a gearbox fault to a 'can't be arsed to check it over' fault

 

[Taipan]

Glad to see its gone from a gearbox fault to a 'can't be arsed to check it over' fault

A recurring theme at Chez Taipan

 

[Steptoe]

There is a sleeve inside the gearlever, you have to remove the bolt that secures the lever to the footrest . You can undo the bolt without removing the footrest or any other parts, if you got some decent tools -

No amount of spraying with WD40 will free it. You have to remove the sleeve and grease it all up . Takes 10 minutes, i did it on judges bike recently while he waited .

 

[Taipan]

There is a sleeve inside the gearlever, you have to remove the bolt that secures the lever to the footrest . You can undo the bolt without removing the footrest or any other parts, if you got some decent tools -

No amount of spraying with WD40 will free it. You have to remove the sleeve and grease it all up . Takes 10 minutes, i did it on judges bike recently while he waited .

Ta Mate, I appreciate the advice.

I took it all off and eventually got the loctited or was it alloy welded in bolt out The inner bolt showed signs of wear-ish. I rubbed it down and buffed it up with 1200 grade paper. Which seemed to help it fit in and out a bit better. I polished up the sleeve bushes with a wooden handle and put some light oil on and reassembled it. It still doesn't drop under its own weight though? But it ddoes move with even pressure and not all unevenly like before.

It does seem to return under the pressure of the gearbox arm spring a lot better though? Should it fall down under its own weight if you take the adjust rod off? If so I'd better get some new bushes and try again?

 

[Steptoe]

Ta Mate, I appreciate the advice. Should it fall down under its own weight if you take the adjust rod off? If so I'd better get some new bushes and try again?

Yes, it should drop down under it's own weight .

don't use oil to lube it - use marine grease or Mobil synthetic grease ( the red stuff) - then it'll stay loose for years .

 

[Taipan]

Yes, it should drop down under it's own weight .

don't use oil to lube it - use marine grease or Mobil synthetic grease ( the red stuff) - then it'll stay loose for years .

I'll get new bushes as it is no where near that lose. I'll get some of that synthetic grease too.
cheers
Dave

 

[Taipan]

I'll get new bushes as it is no where near that lose. I'll get some of that synthetic grease too.
cheers
Dave

Ok, I've done all that, but as soon as I tighten the allen bolt up, I am more or less tightening the gear lever in position??

I assumed I'd lost ashbim or something, but I've checked the parts diagram and there is no shim or washer there?? Why is my gear lever doing this??

 

[Taipan]

Boing. Anyone got any ideas? This is driving me up the wall! Should I buy a new sleeve to go inside the bushes?

 

[littleredrooster]

The bolt should 'bottom out' before it starts to nip the gear lever. Mine seems to have about 2mm end-clearance. Try screwing the bolt in without the lever on and see what dimension you end up with.

 

[Taipan]

The bolt should 'bottom out' before it starts to nip the gear lever. Mine seems to have about 2mm end-clearance. Try screwing the bolt in without the lever on and see what dimension you end up with.

Mine definetely doesn't. If I tighten it right up, I pretty much tighten it in place! I think i'd better just order up a new bolt and sleeve as i cant think what the hell else it could be?

If I back the bolt off a 1/4 off a trun it drops under its own weight fine, but this also means the bolt isn't tight and I'd guess it would work itself out?

Its just so weird, as this was a fault that developed?

 

[pomm001]

I did the same to my 1150 linkage, the centre bolt was held in with loctite , so why not clean the fixing, re loctite and refit to the position
where the lever is free ?

With my linkage no mater how tight the centre screw was the pivot did'nt tighten up.

Was the linkage ever free ? if its tight then either the lever at the pivot is undersize, or the bush ,

i would try the first option