Gearbox woes

[DevonianScotsman]

The latest problem in the Jonesybop GS saga has arisen...

Riding into work this morning on my 100GS, the change lever on the gearbox became quite stiff - Then stuck in 2nd gear. I just about managed to change down to neutral, but its putting up a lot of resistance!

Any ideas?

 

[John Armstrong]

The cheap check, remove, clean and lube up the foot lever and the adjustable linkage. Well known for gearbox problems. That's about the limit of my knowledge, apart from the engine mounting bolt moving and preventing downwards changes.

 

[DevonianScotsman]

Im beginning to think it might be the clutch.
Will tighten the cable - and let you know if i'm still having issues.

 

[John Armstrong]

IIRC 201mm at the gearbox end and 2mm play at the handlebar. If the 201mm isn't correct it can make the gearbox very graunchy.

 

[DevonianScotsman]

Cheers John - I'll check that

 

[BillN]

Im beginning to think it might be the clutch.
Will tighten the cable - and let you know if i'm still having issues.

Bob,

If the gearbox and linkage are OK........you should be able to change up quite easily without the clutch....just get the revs right, (i.e.reasonably high), do not pull the clutch lever in and it will flick into the next gear up......with a bit of a jump forward - (change without the clutch lever pulled in)

Also, when changing down, pull the clutch in and get the revs dead right and you should be able to change down with a crunch or two, (with the clutch level pulled in).

The above of course when you are riding along at road speeds and you do it at your own risk as if you knacker the gearbox, it's not down to me

Should test the gearbox linkage...etc., if you see what I mean

Is the Bike stuck in gear, .............presumably you can find neutral with and without the lever pulled in

Is the clutch stuck in the engaged position?

 

[DevonianScotsman]

I've had a fiddle with the cable adjustment and it seems to be better - changing is smoother and the clutch lever is returning to its full out position, which it wasn't doing before. Getting it into Neutral was a problem, so i'm assuming that it could very well have been the cable adjustment - From my experience with 1980s Jap machines anyway...

 

[Voyager]

I've had a fiddle with the cable adjustment and it seems to be better - changing is smoother and the clutch lever is returning to its full out position, which it wasn't doing before. Getting it into Neutral was a problem, so i'm assuming that it could very well have been the cable adjustment - From my experience with 1980s Jap machines anyway...

From the above, it sounds as though the plunger mechanism between the clutch lever on the gearbox and the clutch pushrod is sticking in the shaft in the gearbox backplate. I believe the later ones were nylon and have been known to stick.

You'd have to remove the swingarm to get to it without taking the gearbox out.

You could try removing the lever and the rubber boot and squirting WD40, or similar, into the hole if it sounds as though I'm right.


Bob.

 

[BamBam]

The cheap check, remove, clean and lube up the foot lever and the adjustable linkage. Well known for gearbox problems. That's about the limit of my knowledge, apart from the engine mounting bolt moving and preventing downwards changes.

I think thats the first step also check gear lever pivit bolt is straight. Grease and replace as nesasery also check seals to gear lever is intact.
IF YOU want to just check the lube situation coupious amounts of WD40 flushed through as you move the lever up and down till the brown stit come out. If it frees up have a ride, then strip and fix

 

[DevonianScotsman]

Cheers for the advice guys

 

[lurcher]

Does it select OK with engine not running?

 

[steveo]

make sure that the clutch cable is nt running to close to exhaust, mine was and it melted the cable inner nylon and made the gear change progresivley worse.

 

[(RIP) Proff]

make sure the oil is ok mine, was graunchy cos a lotof water had got in via dodgy speedo cable boot ...

 

[John Armstrong]

make sure the oil is ok mine, was graunchy cos a lotof water had got in via dodgy speedo cable boot ...

Looks like the speedo drive boots will be having a bit of a test down south etc this wee-kend.

 

[Steptoe]

Lets cut out all the guess work and start at the beginning before you dismantle the bike and spend hundreds of pounds - Will the gearbox change gear without the engine running ? .

 

[DevonianScotsman]

Problem solved!

Problem solved! Tightened the clutch cable - Must've slipped fairly badly. Now all is fine!

Cheers for the advice.