GT125 gear selector issue

[NickMcDonald]

Howdy people. I'm having an issue with my Suzuki GT125 gear selector not returning to 'neutral position'. Ill clutch in, kick up / down a gear.....and it will stay there. It wont spring back to its resting position. I haven't cracked the engine case apart to have a look yet. Is there some kind of return spring that could have dislodged itself? I'm after a bit of insight and an idea of what to look for before I get balls deep in fiddly gearbox bits!

Besides that, the bucket racer is coming along nicely, and Ive made a fair bit of progress lately.....probably due to me actually getting off the couch and into the garage. Engine had its first fire up last weekend and runs really smoothly. If I can just get it to swap cogs properly, Ill be able to take it on its maiden voyage! Cheers.

[saxet]

I suspect your right. There's probably a broken spring in the gear selector mech that will need replacing. From memory there are two springs in there.
You'll probably need to take off the engine casing on the gear lever side, I think.Though it could be the other side.

[Akzle]

I suspect your right. There's probably a broken spring in the gear selector mech that will need replacing. From memory there are two springs in there.
You'll probably need to take off the engine casing on the gear lever side, I think.Though it could be the other side.

+1.

you *should* be able to pop (screw) the side cover off.. it covers the sprocket and whatnut. should be fairly obvious once you're in what's what.

[NickMcDonald]

Ah awesome guys cheers! Ill get into this morning and let you know how I get on.

[Bert]

I suspect your right. There's probably a broken spring in the gear selector mech that will need replacing. From memory there are two springs in there.
You'll probably need to take off the engine casing on the gear lever side, I think.Though it could be the other side.



+1.

you *should* be able to pop (screw) the side cover off.. it covers the sprocket and whatnut. should be fairly obvious once you're in what's what.

Try the clutch side of the engine. The gear selector shaft will go right thought the center of the engine and connect to selector drum behind the clutch. The end of the shaft should have a spring which is held in place on part of the casing. By the sounds of things it may have slipped off this. You should be able to sort it all out with out needing the dismantle the clutch and/or split the casing/gear box. Though you might still need to if it's not the spring...

[TZ350]

Try the clutch side of the engine. The gear selector shaft will go right thought the center of the engine and connect to selector drum behind the clutch. The end of the shaft should have a spring which is held in place on part of the casing. By the sounds of things it may have slipped off this. You should be able to sort it all out with out needing the dismantle the clutch and/or split the casing/gear box. Though you might still need to if it's not the spring...

Another thing to look at is the left side of the motor where the gear selector shaft enters the gear box. Sometimes the shaft is held in place by a circlip and washer and a good bang on the shaft (like in a crash) can dislodge it and allow the shaft to float to the right and when that happens the return spring Bert describes pops off its locating peg. You can often fix it by pulling the shaft back and refitting the clip without having to take the clutch side cover off. I am not sure if this is your problem or even possible on the GT125 but it may be worth a look first.

[Drew]

Definately the clutch side needs to be pulled apart. Clutch drum will have to come off to get to the selector assembly.

System is fairly straight forward. Sing out if you need any parts, I've got a few spares.

[TZ350]

273693

OK ... no reating clip there, but it will probably be that the return spring, item 29 has broken or sliped of item 30. As drew said, you will have to take the clutch cover off to see.

273703

This how the spring should look when its on the shaft.

[NickMcDonald]

Woah cheer for all the feedback guys! I had my good engine apart on the weekend and found chunks of steel kicking around inside. Gulp. Theres a little steel plate, angled at about 45 degrees and held in by two screws. A sort of cam / gear attached to the kick start shaft slides down it, and spreads off from another toothed part of the kick start mechanism. I think the manual referred to it as a 'neutral lockout pawl' or something like that. ANYWAY.....that little bit of angled steel had shattered, and cracked off part of the alloy crank casing that contained one of the screws holding the steel plate down.

I tore down my spare motor and pillaged parts off it to fix my good engine. I used some metal glue to repair the snapped bit of alloy crank casing. Im leaving that to go off, and ill get back into it within a fortnight when Ive got some time in the garage! Again, thanks for the feedback...very much appreciated, and Ill keep everyone posted on how I get on.