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Post Info TOPIC: Sticking gear shifts


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Sticking gear shifts
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Hi all,

I have a couple of questions relating to the TTR gearbox, hopefully the collective genius of the forum can help me!

I've had a couple of occasions recently where I get stuck in first gear. Gear changes on the low gears can also tend to seem very stiff / like they are not engaging properly. Higher gears seem fine. Switching into neutral seems to be practically impossible due to the amount of force needed to change up or down.. this is slightly different from when the gears get stuck though. I have to do it by hand after stopping the bike usually. Note that the gears can also free up and be light and normal to shift...

I've done a search on the forum and compiled the following list of things to check/try:

* change oil (I've done a change fairly recently though so I don't think this will help)

* check wear on sprockets and chain

* check chain tension

* check loose post - https://ttr250.activeboard.com/t62131229/gear-problems/?page=1#comment-62132219

Lastly, if I do need to open the left hand crank case, is this something I can do with the bike lying on its side or do I need to fully remove the engine?

Are there any other things worth checking once I have the bike open?

Any other hints or tips would be greatly appreciated!

Cheers

Rob

p.s. I'm guessing it is that loose post and when it falls in or out of place it is giving me smooth or difficult gear changes.. opinions please!



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Super Guru

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is your clutch clearing properley does it drag does it lurch forward when you select first gear also is your tickover high john i woul think your clutch is not clearing

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Thanks John. Will check clutch cable tension in the morning too.

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Super Guru

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Agree sounds like the clutch adjustment is the last thing before taking the cover off 

If it's dragging a bit it could be making the shifts hard 



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Super Guru

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Not wishing to be over pessimistic but it could be more than one issue Rob cry

Difficulty finding neutral with the engine running is often caused by the clutch basket "fingers" developing notches that grip the plates such that they don't free off when the clutch is pulled in. The photo below shows where you need to check. This basket just happens to be in good condition. 

Not the end of the world if yours is worn as the fingers can be carefully filed back flat wink

You can remove the cover with the bike on its side and you won't lose the oil.

7-plate clutch basket 4a.jpg

 

Also worth checking the position of the pointer on the operating arm.

clutch_needing_adjustment.jpg

clutch_adjusted.jpg

 



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Exeter, Devon, UK

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Hi Brian,

Thanks for your amazing advice as usual! I'm going to try and do the trouble shooting and check all these things at the beginning of next week if I have the time. Thanks again, massively appreciate the advice and photos!

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Well I had an interesting day.

Went for a ride this morning and thought about the advice given here so adjusted the clutch cable using the bolts at the lever.. suddenly I can get into neutral and gear shifts seem much better.

So I then order a new clutch cable since I think the one on the bike is stretched or something..

Afternoon rolls around and a mate says lets go for a ride, so we do and when we get out to the furthest point we stop and decide to switch bikes. He jumps on the TTR and we're about to pull off and the clutch cable snaps! ****. We switch back and I follow him back towards home clutchless shifting which is all going fine until we get to a junction to a fast road (the only junction on the way back since we took the back roads to avoid them) and I stall the bike. Try to start the bike again and switch into first but something gives in the engine. Double ****!

Leave the bike in the pub car park by the junction and he gives me a lift back to the van which we then use to go and retrieve the bike.

We took the fuel tank and top case off the engine and everything seems fine. Tested compression the tester and that seems OK so it seems like the top end is fine. Checked for spark and no dice. Maybe the coil has somehow also died?

Tomorrow going to try sticking on a different coil and kicking her over to see if she starts, if she does then it must be something in the gearbox that is gone, he reckons possibly starter gear.

What a day.

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Super Guru

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Were you trying to start in gear? Without the clutch inhibitor switch activated the starter won't spin.
Or did you start the engine then try crashing into 1st and there was a bang? That sounds a bit nasty, might need a bit of surgery.
Bad luck

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Thanks for the tip mossproof.. bike in neutral!

Gently as possible shifting into first on the flat seemed ok the first time but on the second time I think it was the upward hill start that did it in.

Will get her guts out tomorrow and have a proper look then report back.

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