Gearbox stuck...

Vincent

Vincent

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Hi,
I haven't had time to look into it much but it looks like my gearbox is stuck in 3rd or 4th gear. Clutch seems to be operating as normal but gear won't change, that doesn't sound good... What do you think it could be? Does it mean a gear box rebuilt?? The bike is a R65GS from 1991
Cheers
 
Suspect a broken detent spring, coppers to buy but the gearbox has to be opened up to fit it.
But I,m sure one of the airhead experts will be on here to give a more detailed diagnosis
 
To find out if it is yer spring for sure
Tip yer bike over on its side ( right over ) then you should be able to change to another gear = find neutral
I was told this by an airhead gearbox specialist as a tip for getting you back to a garage if yer bike sticks in 5th gear

The tip was If yer bikes stuck in top gear and you cant select other gears,
its probably yer selector spring, tip yer bike over and get a gear you can drive home/te garage with and sort it out there

There is a chap in huddersfield that re-furbishes um sorry I have forgot his name but he is in the unit next door to Tony Archer the world famous upholsterer Give Tony a ring and he will give yer the blokes number
Last time I spoke to him the price was 100 quid plus parts used
HTHY :thumb2
 
Steptoe said:
But don't overlook the gear change arm/lever that bolts into the box. The bolt can come loose which means it won't change gear. Takes seconds to check and fix...
Click to expand...

This happened to me years ago peak traffic down embankment one afternoon, luckilly enough the bolt just came loose and did not fall out :blast
 
Thanks for the replies,
I think I'm stuck in 2nd gear so it was not a big problem bringing the bike back to the garage. The gear lever bolt is not loose and I do still get spring pressure on on the lever. How hard is it to get the gear box out? I'll have a look in the Haynes.
Cheers
I'll be back
 
I see that winderlich list a tool that can be used in this situation to change the gear and get you home. You apparently insert the tool into the gearbox via the fill hole and use it to change into whatever gear you want. I'd never heard of this before. The tool is very simple looking and I'd imagine easily replicated.

Anyone here ever just made up such a tool?

http://www.wunderlichamerica.com/motorcycle/R100GS/2399541.html

Just spotted they have video and some pics of the tool set against the standard tool kit. I have some 5mm stainless rod that I think would be perfect for this, tools surely don't come much easier to make than this one. I figure if you understand how the gearbox works you don't even need the instructions.
 
The light "small pawl return spring" holds the escapement lever (the lower one) up so that the teeth can engage with a 'cage' in the centre of the cam plate.

If the spring breaks the lever drops down and the gearchange won't work.



DSCN0262.jpg



Its not easy to see, but its sandwiched in here:


DSCN0305.jpg



Turning the bike upside down drops the teeth back into the cage and a suitable gear can be selected (2nd or 3rd) - you can then get home (slowly).

The simple tool that is poked in through the filler plug hole is just lifting the escapement lever back into mesh so that the gears can be changed. Its easier, and less messy, than turning the bike over but the effect is the same.

The spring is £1.49 from Motorworks - but the gearbox has to be stripped to replace it - its a Bummer when it goes :blast.

Getting the gearbox out and back in isn't particularly difficult, just a bit fiddly in places. I did one recently and took a few pictures - see here:

http://www.ukgser.com/forums/showthread.php/389935-Newish-member-Blown-gear-box


Just shout if I can help :thumb.

Bob.
 
BMurr said:
I see that winderlich list a tool that can be used in this situation to change the gear and get you home. You apparently insert the tool into the gearbox via the fill hole and use it to change into whatever gear you want. I'd never heard of this before. The tool is very simple looking and I'd imagine easily replicated.

Anyone here ever just made up such a tool?

http://www.wunderlichamerica.com/motorcycle/R100GS/2399541.html

Just spotted they have video and some pics of the tool set against the standard tool kit. I have some 5mm stainless rod that I think would be perfect for this, tools surely don't come much easier to make than this one. I figure if you understand how the gearbox works you don't even need the instructions.
Click to expand...

26 dollars for a bent tentpeg :eek

2399541.jpg
 
I'd guess the groove and notch are to locate the tool correct depth into gearbox and to locate it on the cam or whatever the thingybob watchyamacallit in the box is called. Could someone reverse engineer it using an open gearbox and post its doimensions as a sticky here?

Icing on the cake would be a video of said tool operating the mechanism of an open gearbox.
 
BMurr said:
I'd guess the groove and notch are to locate the tool correct depth into gearbox and to locate it on the cam or whatever the thingybob watchyamacallit in the box is called. Could someone reverse engineer it using an open gearbox and post its doimensions as a sticky here?

Icing on the cake would be a video of said tool operating the mechanism of an open gearbox.
Click to expand...

What an excellent idea. I for one would buy one - mad not to really seeing the poss benefits and the ease of carrying it around...:thumb2
 
SteveM said:
You could also open sardine tins with it - so it's a multitool.
Click to expand...

Too right it is, also a good nose and ear picker or back scratcher. Make the end sharp and it could be a meat hook or a hook in case you lose your hand and want to do pirate impressions, feckin hell the possibilities are endless-someones going to patent it and make millions. Someone like steptoe or Bob farmer will make the video andbn be famous and get paid a fortune by Youtube.:D
 
MickDB1 said:
To find out if it is yer spring for sure
Tip yer bike over on its side ( right over ) then you should be able to change to another gear = find neutral
I was told this by an airhead gearbox specialist as a tip for getting you back to a garage if yer bike sticks in 5th gear

The tip was If yer bikes stuck in top gear and you cant select other gears,
its probably yer selector spring, tip yer bike over and get a gear you can drive home/te garage with and sort it out there

There is a chap in huddersfield that re-furbishes um sorry I have forgot his name but he is in the unit next door to Tony Archer the world famous upholsterer Give Tony a ring and he will give yer the blokes number
Last time I spoke to him the price was 100 quid plus parts used
HTHY :thumb2
Click to expand...

roger bennett really nice guy
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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