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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Hard to downshift
Post Info TOPIC: Hard to downshift
pjkr199


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Hard to downshift
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Hi all. Hope you're having a good day. 

 

I'm hunting for a ttr, found one in Cornwall, the Open Enduro, but it's problematic. Talked to the guy on the phone, sounded reasonable and no bull****, he said it's hard to downshift. Shifts up well. He thought it's a clutch, replaced, but problem persists. 

I'm wondering what could it be? I have some mechanical knowledge about bikes, but never had to tinker with gear boxes. 

Depending on what could be the problem, I might consider buying it, if repairs are not too difficult (like taking gearbox apart - I could do it but not sure if I'm ready for such endeavor). 

 

Many thanks in advance for your help. 



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TTRfan


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It is rare for a TTR to have gear change issues. What he describes could be that the return spring's retaining post inside the gearbox may have broken free cry

The fix is to TIG weld it back in.

This assumes that the gear lever is on tight and not slipping on its spines.

Personally I can't see that the clutch could be to blame as it's possible to down change without pulling the clutch if need be. 

Gear spring retaining peg.JPG

Gearcase needing welding 001.jpg



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pjkr199


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Thank you for such a detailed answer. Definitely helps to see what you're talking about.

If the problem is what you say, would it not refuse to shift down at all? Guy says it's difficult, but you can get it to downshift.

Also, what sort of amount of work this might involve? Is it removal of the cover and sorting that bit out? I never even seen a ttr in flesh so can't imagine what it would involve.

Also, could it be gear linkage problem?

Many thanks



-- Edited by pjkr199 on Saturday 6th of June 2020 12:38:48 AM

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Forgorin


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Ttrfan is the boss when it comes to trouble shooting!

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TTRfan


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pjkr199 wrote:

Thank you for such a detailed answer. Definitely helps to see what you're talking about.

If the problem is what you say, would it not refuse to shift down at all? Guy says it's difficult, but you can get it to downshift.

Also, what sort of amount of work this might involve? Is it removal of the cover and sorting that bit out? I never even seen a ttr in flesh so can't imagine what it would involve.

Also, could it be gear linkage problem?

Many thanks

I can't think what else it might be. You would have to take the clutch cover off to see what's going on onside. My recollection is that you can still shift gears  (sort of) with the post loose.

The TTR doesn't really have a gear linkage as such. The gear change shift shaft comes in from the gear lever on the LHS and engages with the shift mechanism shown in the photos.

 



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pjkr199


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Thanks.

The bike has been sold, but nevertheless I've learned something new, I say thank you.


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