LF200GY-5 Transmission doesn't shift
 

2007 LF200GY-5 / 1064 km

Transmission won't shift, shifter moves but doesn't feel right, clutch works. Bike will move under it's own power, just can't shift gears...

Removed kickstarter, rear brake pedal, disconnected clutch cable, thirteen (13) 8mm bolts securing clutch cover/case. Tapped on cover/case with wooden block until it broke loose from gasket... gasket was undamaged and reused. Found the bolt that secures stopper-plate to shift-drum loose and partially backed out. Stopper-plate no longer engaged pin mounted on shift-drum, or spring loaded stopper-arm (with roller) that holds transmission in gear.

Used circlip pliers to remove circlip holding gearshift plate. (circlip, spring, then plate) Removed gearshift plate, bolt that secures stopper-plate, and stopper-plate. Held stopper-arm out of the way so stopper-plate could be positioned to engage alignment pin on shift-drum. Used thread locker on bolt and secured stopper-plate to shift-drum. Make certain the roller on stopper-arm rolls against stopper-plate.

Replace gearshift plate, spring, and circlip... I used anti-seize compound on bolts during installation of clutch cover/case. Grease shaft on brake-pedal when you install, and use new cotter pins. Start to finish was four hours, including lunch break, pictures, clean-up, and test ride. Bike is now back in everyday service, shifts better than new.

http://i226.photobucket.com/albums/d...0239Medium.jpg

http://i226.photobucket.com/albums/d...h_DSCN0241.jpg

Great Pictures, Thanks....

nice work. your pics/info I will be saving for my "rainy transmission day"

Very nice work!

Nice post :D

Phil, Thanks for taking the time to put this all up in post. Isn't that the new counter balance shaft engine?

Yes, this is the counter-balanced OHV (pushrod) engine.

NICE :lol:

Great Post!
Very clear and concise. Fantastic pics. I think this could be kept in the tech info section permenantly. :wink:

Very cool post. Learn something everyday.

Good deal, and the best part is you fixed it yourself. Nice work and thanks for sharing.

Great detailed post. Thanks.

Nice job, thanks for the detailed post...

Thanks Phil,
It is posts like this one that make "China Riders" so important for all of us.

I created a sticky for great post like this. This one has been added.

Thanks Phil

Allen