LF200GY-5 Transmission doesn't shift

Phil_R · 06-24-2008, 05:14 PM

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.

06-24-2008, 06:01 PM

Great Pictures, Thanks....

alonzo · 06-24-2008, 06:45 PM

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

liverchip · 06-24-2008, 06:48 PM

Very nice work!

AZ200cc · 06-24-2008, 06:56 PM

Nice post

dieselhead · 06-25-2008, 12:43 AM

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

Phil_R · 06-25-2008, 01:46 PM

Quote:

Originally Posted by dieselhead

Isn't that the new counter balance shaft engine?

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

Rizn · 06-25-2008, 02:00 PM

NICE

IronFist · 06-25-2008, 02:48 PM

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

lego1970 · 06-25-2008, 04:49 PM

Very cool post. Learn something everyday.

red2003 · 06-25-2008, 06:57 PM

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

kczukiman · 06-25-2008, 07:54 PM

Great detailed post. Thanks.

DirtRoadKing · 06-25-2008, 09:31 PM

Nice job, thanks for the detailed post...

squire · 06-26-2008, 08:43 AM

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

katoranger · 06-26-2008, 11:14 AM

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

Thanks Phil

Allen

06-24-2008, 05:14 PM	#1
Phil_R Join Date: Sep 2007 Location: Live Oak, FL Posts: 43	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. __________________ Phil '18 FXBB Softail Street Bob '17 Tacoma TRD Last edited by Phil_R; 12-29-2017 at 02:43 PM. Reason: pictures
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06-24-2008, 06:45 PM	#3
alonzo Join Date: May 2008 Posts: 527	nice work. your pics/info I will be saving for my "rainy transmission day" __________________ ALONZO 2007 Lifan a.k.a lucy lu. 2,000 miles of good riding.
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06-24-2008, 06:48 PM	#4
liverchip Join Date: Nov 2006 Location: Mystery Spot Posts: 1,223	Very nice work! __________________ 2009 XR650L Big Red Pig Tusk bar risers 2007 X-Moto(Jetmoto) GY250 --mods--- 15/40 sprockets UNI Pod Filter 2007 Shineray TMS 200XYi--Betsy Betsy Mods:______________________ Acerbis DHH headlight FMF Powercore pipe Uni Pod Filter
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06-24-2008, 06:56 PM	#5
AZ200cc Join Date: Apr 2007 Location: Show Low Arizona Posts: 2,889	Nice post __________________ <br />2001 Suzuki DR200SE<br />1997 Suzuki RM250 YIKES<br />1995 Yamaha Breeze 125 daughters<br />1991 Honda XR80r Restored<br />maybe a 2003 Yamaha TTR90
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06-25-2008, 02:48 PM	#9
IronFist Join Date: Apr 2007 Location: Toronto Ontario Canada Posts: 2,585	Great Post! Very clear and concise. Fantastic pics. I think this could be kept in the tech info section permenantly. :wink: __________________ IronFist ___________________________________ The "chain" of command is used for beating spammers. ___________________________________
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06-24-2008, 06:01 PM	#2
Guest Posts: n/a	Great Pictures, Thanks....
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06-25-2008, 12:43 AM	#6
dieselhead Join Date: Jan 2008 Location: Catskill Mnts NY Posts: 85	Phil, Thanks for taking the time to put this all up in post. Isn't that the new counter balance shaft engine?
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06-25-2008, 02:00 PM	#8
Rizn Join Date: Apr 2008 Posts: 127	NICE
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06-25-2008, 04:49 PM	#10
lego1970 Join Date: Apr 2008 Location: Blue Springs, Missouri. United States Posts: 505	Very cool post. Learn something everyday.
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06-25-2008, 06:57 PM	#11
red2003 Join Date: Jan 2007 Location: Northern Vermont, USA Posts: 1,218	Good deal, and the best part is you fixed it yourself. Nice work and thanks for sharing. __________________ 2006 Roketa RSX200E MODS: YZ250F Muffler, Airbox delete with K/N style filter, Main Jet reamed 2 sizes over, Yamaha R1 Rear clicker shock on custom scissor linkage making 8 3/4in. of rear wheel travel!!! Battery relocated under seat.
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06-25-2008, 07:54 PM	#12
kczukiman Join Date: Jul 2007 Location: Independence,Missouri Posts: 1,049	Great detailed post. Thanks. __________________ Kman 2007 HI-BIRD 250 2007 Vbike V4S 250
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06-25-2008, 09:31 PM	#13
DirtRoadKing Join Date: Mar 2008 Location: Florida Posts: 146	Nice job, thanks for the detailed post... __________________ 2001 HD Roadking 2008 Hi-Bird/Ricardo http://www.chinariders.net/gallery2/...g2_itemId=8088
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06-26-2008, 08:43 AM	#14
squire Join Date: Jan 2008 Location: central Arkansas Posts: 79	Thanks Phil, It is posts like this one that make "China Riders" so important for all of us. __________________ Squire, http://lifanlf200gy-5.blogspot.com/ http://1948model.blogspot.com/
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06-26-2008, 11:14 AM	#15
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I created a sticky for great post like this. This one has been added. Thanks Phil Allen __________________ You meet the nicest people on a Honda Clone.
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