GY200 won't shift up - only first and neutral work

[Quinn]

Hello everyone, thank you in advance for any help! I have a gy200 with a 163fml engine that will only shift from neutral to First, there is no up shifting ability whatsoever. I have pulled the clutch cover case but I cannot find any diagrams on the internals. I don't know what everything should look like where is spring or something is missing. It looks as though the little shift arm slides off of the star shaped piece that actually changes the gear. I'm not sure if there is some sort of tensioner or spring that is missing. I have attached pictures. If I hold that little shifter arm with my finger I can shift through the gears if I let it go it will shift once and then just slide off of the star. Hope that helps, all the best

[JerseyTBR7]

I know this may sound silly, but did you check your shifting lever is not bent into the housing preventing it from going up?

It happened to me on the trails and had to bend it out.

I hope it is that simple for you. Otherwise, best of luck.

[JerryHawk250]

From looking at the picture everything looks normal. May just be some wear on parts. Even though this is for a 125cc engine the design is still the same. Here's a link to the manual to help you understand how the shifting mechanism works. http://die-kleinkraftrad-ig.de/wisse...itungcg125.pdf

[JerryHawk250]

Looking back at the pictures again it looks like the spring on the roller arm is broke.

[Quinn]

I'm kind of stuck right now. I can't figure out how to remove the clutch because it's held in place by another wheel to the right of it. I don't know how to take that wheel off.. I tried to shift through the gears and I can see it working, up and down but it stops and won't go any further. I'm not sure what the names of these parts are. I'm pretty good at figuring things out. But right now I'm stuck. I believe the roller arm is what applies pressure to the star, that has a very strong spring on it and is applying pressure to the star when the gears are shipped it through.

[JerryHawk250]

download the manual i linked in the previous post.

[Quinn]

I downloaded the manual and it really helped as far as seeing the parts and how they go together. I see there is a spring behind the shifter arm, I'm not sure if that's the right terminology, and then there is a small spring on the outside portion and it is retained by a clip. It doesn't feel like there is any sponginess behind it. Meaning if I push on it I don't feel the spring behind it. Also, what is the name of the tool to remove the clutch?

[JerryHawk250]

You will need a oil filter nut removal tool like this to remove the filter before you can remove the clutch.
https://www.ebay.com/itm/Engine-Oil-...Cclp%3A2334524
Or you can make your own from a large deep socket and a grinder if you don't want to wait for it to come from china.

[Quinn]

Haha, I actually Googled it and then found one on Amazon for 8 bucks. Made specifically for peace China bikes and Hondas Etc. I really do appreciate the help. About the pull the clip off, fingers crossed I find the problem

[Quinn]

So I bought a circlip pliers and removed the clip along with the spring and shifter arm, or whatever it's called. This is what is left. I'm not sure I see anything wrong. Anyone? I have attached two pictures of where I'm at. It's possible that something was out of alignment but I didn't notice it and I kind of pushed things around. Mainly that backer fight that was behind the shift arm. I'm just thought skilled when it comes to Transmissions. Give me a carburetor!!!

[franque]

It's really hard to see the pictures, but I have another idea. Does shift when running, or have you only tried to shift it while the engine is off, while stationary?

[grumpyunk]

The images are HUGE and impossible to see w/o scrolling back and forth. *I* sure wish they could be downsized to a 'standard' of some sort, with links to the LARGE, very exacting images.
Gotta click and move and do some fiddling before making a bigger fool of myself.
tom

[grumpyunk]

Well, whatever. I can't see the images for SH*T. Scroll back and forth, try in a secondary tab/window, and phhhhht. Grabage.
It appears that the fork that flops around on the end of the star shaft has decided to lay low, which means it won't be able to push on the HIGH side of the star, and rotate the shift cylinder in that direction.
I would look at the 'centering' mechanism, likely a buncha springs, that will 'tend' to put the 'fork' (MY WORDS) back into a position, after a shift, where it can go LOW to turn the star in one direction or the other.
gonna quit before my browser BLOWS UP and throws this onthe floor.

[Quinn]

Thanks for the feedback Grumpy, I'm sorry the pics are so enormous. This forum uses an old outdated 1990s skeleton for its internal framework. Its not streamlined for attachments. I went over everything, put it back in place and sealed the cover. Will test today and give feedback
Tick tock tick tock...

[Quinn]

So I just watch some YouTube videos of somebody with a hawk 250 that took the clutch cover plate off because he had the same problem. I know it is a different motor however it has the same internal parts. In his video the roller arm with the spring that applies constant pressure is actually positioned in the bolt hole just below the shift drum. You can see in my pictures that hole is completely open as if something is missing. However in his video his hole is completely open but it looks more like an oil Port than just an Open bolt hole. Is it possible someone opened it up and put the roller arm in the wrong place? If anyone wants to see the videos they are on YouTube "hawk 250 right cover plate off pt 2". Let me know!!!