n00b here with a free but broken bike

[slakr7555]

hi everyone, i was given a broken yamoto gy200 dualsport and ive got a few questions because apparently, as ive found, info on chinese bikes is almost non-existent. i knew the bike had trans issues when i got it but my main focus was stripping all the electrical bs off of it first. i used to race motocross and i dont really like enduros what with the lights and switches and garbage. sorry. so i stripped the bike and got it running with bare minimum. once i started the bike i noticed the clutch felt horrible and i could feel first and second gear click but no action. i figure the clutch is garbage but y no other gears? i have no manual so i have no idea how this trans is sposed to be put back together and all i know is my friends neighbor who gave it to him only took off the right cover to repair the clutch bearing so the main case is untouched. either he didnt put it back together right or its missing some part or something else is broken i just dont know. anyone have pics or diagrams or a manual so i can see how this thing is sposed to go back together? ive searched and found a couple pics but they didnt help me at all. thanks everyone this bike is greek to me as im used to 2 stroke jap bikes

[culcune]

I was, and still am, mechanically disadvantaged. Several years ago, I managed to kill one of these 200s in my Jetmoto, and ordered a Lifan 200 from Ebay to replace it. The guy who installed it was a backyard mechanic who put it in, and it ran well. However, the tranny seemed to go out one day riding 20 miles back from work. Lost interest/confidence, parted it out, and sold the chassis with engine to a member here...it turned out to just be a wrong sized clutch cable (I believe it was just the reused cable from the original engine (which was a Zongshen engine vs. the replacement Lifan engine). Start there, if the engine is still running.

[slakr7555]

thanks, ill give that a shot. anything else guys?

[Wild_Alaskan]

with these motors buying a replacement is just about easier than fixing them. If i am understanding right it runs right in 3rd gear and up? Transmission work requires some special tools to split the cases and then you would have to find someone selling that individual part or parts you are replacing.

[slakr7555]

no i can grab 1 &2 but thats as far as i can get. the rest arent there the selector goes stiff.

[slakr7555]

honestly it feels like the cam is stuck to me, or a fork is jammed

[humanbeing]

The plate(s) /spring(s) may be f***ed
[youtube]LnPktdVsIyU[/youtube]

[Weldangrind]

I think that Humanbeing is saying that the clutch is the issue. Certainly could be. Can you throw up some pics of your motor, so we know what we're dealing with?

[slakr7555]

sure can. ill have em up soon

[slakr7555]

also, that little rod in the side case, (the one with the arm that the clutch cable connects to) is that seriously what actuates the clutch? thats like 80's tech.

[slakr7555]

sorry for the large images. the springs and outer plate have been removed but thats about as far as ive gotten till i can find an impact driver.
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[Corvairkid]

i'm by no means an expert but dont most M/T's have synchro-dogs in them i had an issue like this in my corvair and the syncro dogs where jammed side ways in between 3-4 gear

[SpudRider]

Motorcycle gearboxes are not synchronized; they are sequential, dog-engagement gearboxes. The following video demonstrates how a six-speed, constant mesh, un-synchronized transmission works in a motorcycle.

[Weldangrind]

Cool vid! I haven't seen a gearbox animation like that before.

[SpudRider]

Originally Posted by Weldangrind

Cool vid! I haven't seen a gearbox animation like that before.

Thank you, Weld.

If you wish, you can visit the following website which clearly explains how the transmission in my Honda XR650L operates.

http://www.justxr.com/jaw/gearbox.html

Here is the operation of 1st gear.



Here is the operation of 2nd gear.



Here is the operation of 3rd gear.



Here is the operation of 4th gear.



Here is the operation of 5th gear.



The five-speed transmission in the XR650L/XR600R works exactly as shown in the following video. However, since the video demonstrates a six-speed transmission, merely disregard 4th gear in the video. Gears 1-3 work exactly as shown, and the last two gears demonstrate how 4th gear and 5th gear work for the XR650L/XR600R transmission.