Author Topic: Clunky gear change  (Read 1528 times)

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Offline pgnz

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Re: Clunky gear change
« Reply #5 on: May 24, 2013, 10:57:26 AM »
Yeah no high idle,  1000 revs running smoothly is good,  should be able to tick over at 500 revs on the verge of stalling at 400 revs when warm,  but if idles too low the engine compression gives a jerky ride in town,  you want a bit of revs at idle. XS gearboxes, they're all clunky,  1st gear from neutral with engine running,  the first gear cog is spinning fast in there from inertia all the time,  the clutch doesn't stop it,  it's a crunch from neutral,  1st gear slams in hard no matter what,  better to start in gear,  clutch in.  Changing from 2nd to 3rd to 4th with no clutch if the timing's all good it's pretty smooth.  A newly lubed clutch cable is good value,  pump gloopy oil all the way thru the cable with a syringe and hose

Offline excess.11

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Re: Clunky gear change
« Reply #4 on: May 24, 2013, 07:05:37 AM »
No problem Nev...........but do let us know progressively what actions you try and the results and final outcome as it serves as a log  on here for others  to research if they encounter a similar scenario. :)

Offline LUKEY

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Re: Clunky gear change
« Reply #3 on: May 23, 2013, 07:20:27 PM »
Thanks for your great input Jeff,cheers Nev

Offline excess.11

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Re: Clunky gear change
« Reply #2 on: May 19, 2013, 07:35:32 AM »
Along with the oil change.....use a mineral oil...as opposed to one with synthetic additives as these may promote clutch slippage.
Idle speed should be around 1100 rpm.

http://www.datateck.com.au/Lube/PenriteAus/

 Start with carrying out the clutch plate and clutch cable adjustments as per service manual.
Physically disconnect the clutch cable from both ends and check there is no binding and it slides freely in the outer sheath..........any snagging or stiffness in it s ability to move..............replace the cable.
It would actually be something worthwhile for the price of one just to eliminate it as it may catch friction under tension /
operation. You would probably see this at the return of the lever on changing. There should be a half inch or so freeplay at the end of the lever before you feel clutch pressure.
I m assuming you have changed the oil and filter from when it has been sitting for so long. I may even suggest after a couple of reasonable rides..........you change it again to really flush out any old oil residue.
These bikes do have a tendancy to  "clunk" into first gear from time to time........especially on first start up .

The fact that you say it occurs in other gears sounds like it s clutch related.

The main thing to find out..........is it gearbox/clutch related.............or is it a  ...........drive train / back wheel isssue....or other.
Raising the rear wheel off the ground and rotating/pulling on it in different directions with it in gear as well as in neutral to see if there is anything abnormal .
With the bike in  gear and the rear wheel off the ground..............have someone pull the clutch in ....or use a cable tie to hold it.......... then rotate the rear wheel to check the clutch has released.
Try this when the bike/engine is cold ......................as well as after a short run to warm things up......to compare.
The gear shift selector may also need inspection.......but start with adjustments /oil changes .....then try to narrow down where the problem may actually be after that.

One other point to note is you say it is rev related............carrying out synchchonising and  the colortune operation on the carbs has a direct effect on how the engine/revs and the rate at which the engine settles down inbetween gear changes.
For example..........out of tune carbs...........don t allow the engine to go back to idle with the revs tending to hang ....on changing gears .....
once adjusted properly....  a quick blip on the throttle should see no lag.........or hanging on revs.....the engine should settle quite quickly.
Gear shift lever  linkages should be adjusted and checked as well.
Hope this helps.
Jeff
« Last Edit: May 19, 2013, 05:49:22 PM by excess.11 »

Offline LUKEY

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Clunky gear change
« Reply #1 on: May 18, 2013, 07:55:29 PM »
Hullo all,I have just finished the installation of a DJP sidecar onto my 78 E model,haven't ridden this bike much although have owned for 10 or so years but I notice that unless I am very careful changing gears I get a clunking sound as it goes into the next gear,if the revs on change are up a little the clunk almost goes away but if I let the revs more or less go back to idle it is more clunky,any thoughts on maybe a different grade brand of oil perhaps?appreciate any comments and ideas,cheers Nev