CafeWill
New Member
Hi there!
I'm not sure if this should be posted here or in 1800CafeHelp, but anyway...
I'm building a DT250, the bike came in the form of a heap of parts in boxes for $600. The previous owner had spent a bit of money on the engine, with a new Wiseco piston, Hot Rods con-rod, balanced roatating assembly, new clutch and new reeds. The frame and engine had also been powder coated black, and it came with new rear shocks and a heap of unopened new parts, it was like Christmas!
My plan is to eventually turn the bike into a 70s style GP racer, and ride it on the road. I'll get it up and running as a dirt bike first though and have some fun on it! I've fired the motor for the first time, and it sounds strong and revs up nicely!!
However I've hit a bit of a wall in the build, and it's in the gearbox...
I can select 1st, neutral and 2nd gear quite nicely but when I try for third the shifter moves, but not far enough to engage 3rd gear. I've pulled the shift mechanisms off and the problem looks as though it's inside the cases somewhere... yuck!
I've uploaded a video for a better understanding of the problem. You can hear a dull 'knock' when I try for third gear, it definitely sounds like something fouling inside the cases. My guess is shift forks.
<iframe width="560" height="315" src="http://www.youtube.com/embed/JP8fh6MRmEI?rel=0" frameborder="0" allowfullscreen></iframe>
I'm basically fishing for ideas on how to approach this before I go and split the cases... Which I really don't want to do. On the other side of the gearbox are some plugs, but I don't think I would gain much by removing them.
I have a workshop manual here, so hopefully I have half an idea of what I'm doing when I split the cases, I just have no idea what I'm going to find!
Any help would be greatly appreciated!
Thanks, Will
I'm not sure if this should be posted here or in 1800CafeHelp, but anyway...
I'm building a DT250, the bike came in the form of a heap of parts in boxes for $600. The previous owner had spent a bit of money on the engine, with a new Wiseco piston, Hot Rods con-rod, balanced roatating assembly, new clutch and new reeds. The frame and engine had also been powder coated black, and it came with new rear shocks and a heap of unopened new parts, it was like Christmas!
My plan is to eventually turn the bike into a 70s style GP racer, and ride it on the road. I'll get it up and running as a dirt bike first though and have some fun on it! I've fired the motor for the first time, and it sounds strong and revs up nicely!!
However I've hit a bit of a wall in the build, and it's in the gearbox...
I can select 1st, neutral and 2nd gear quite nicely but when I try for third the shifter moves, but not far enough to engage 3rd gear. I've pulled the shift mechanisms off and the problem looks as though it's inside the cases somewhere... yuck!
I've uploaded a video for a better understanding of the problem. You can hear a dull 'knock' when I try for third gear, it definitely sounds like something fouling inside the cases. My guess is shift forks.
<iframe width="560" height="315" src="http://www.youtube.com/embed/JP8fh6MRmEI?rel=0" frameborder="0" allowfullscreen></iframe>
I'm basically fishing for ideas on how to approach this before I go and split the cases... Which I really don't want to do. On the other side of the gearbox are some plugs, but I don't think I would gain much by removing them.
I have a workshop manual here, so hopefully I have half an idea of what I'm doing when I split the cases, I just have no idea what I'm going to find!
Any help would be greatly appreciated!
Thanks, Will
