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P180/gear shift/gear jumping


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#1 avinrichards

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Posted 09 June 2010 - 05:50 PM

History of the bike:
Pulsar 180 V1
2004 make
72k kms  old

The problem :

Off late i have been having trouble with the gear shifting basically very hard shifts.

The main area would be from 1st gear to second gear. It feels as though its stuck and no amount of force can change it. The only way to get it to shift is to rev beyond 5k RPM.

Similarly once the gear is shifted sometimes there is a tendency for it to jump back a gear , ie from say 3rd to 2nd .

The last clutch plate change would have been about 15k kms ago.

#2 v.v.shyam

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Posted 10 June 2010 - 10:27 AM

avinrichards said:

History of the bike:
Pulsar 180 V1
2004 make
72k kms  old

The problem :

Off late i have been having trouble with the gear shifting basically very hard shifts.

The main area would be from 1st gear to second gear. It feels as though its stuck and no amount of force can change it. The only way to get it to shift is to rev beyond 5k RPM.

Similarly once the gear is shifted sometimes there is a tendency for it to jump back a gear , ie from say 3rd to 2nd .

The last clutch plate change would have been about 15k kms ago.

Did you check clutch free play at clutch lever ?
Venkat Shyam,BV
Motorep
Bangalore

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Bangalore
Email :v.v.shyam@gmail.com
IIMB mail :venkat.shyambv@alumni.iimb.ernet.in
(M): +91 9243 00 3337

#3 avinrichards

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Posted 10 June 2010 - 03:58 PM

yes. Checked that. Its there slightly maybe about 2 cms of movement.

#4 v.v.shyam

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Posted 11 June 2010 - 03:25 PM

2 cms??:) where did you check ?

between the lever & the holder it has to be about 2~3mm
Venkat Shyam,BV
Motorep
Bangalore

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Email :v.v.shyam@gmail.com
IIMB mail :venkat.shyambv@alumni.iimb.ernet.in
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#5 avinrichards

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Posted 12 June 2010 - 03:03 AM

v.v.shyam said:

2 cms??:) where did you check ?

between the lever & the holder it has to be about 2~3mm

Err.. i think we have a small confusion :)

At full expansion i.e. when the clutch is not depressed at all the free play before the clutch starts to engage: that's about a 1 cm.

The 2 cm i was talking is about the clutch lever moving up and down .

Is the 1 cm of movement the problem ? because i adjusted  the clutch and and at any position i have about that much play.

#6 avinrichards

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Posted 15 June 2010 - 03:45 PM

ok sir an update,

i adjusted that the amount of freeplay , but the problem still persists ! :P

#7 v.v.shyam

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Posted 15 June 2010 - 06:03 PM

run the clutch drag test

1. Put the motorcycle on centre stand
2. Ensure that the Rear wheel is free from the ground
3. Start the engine
4. depress the clutch lever & shift to 1st gear
5. Don't release the clutch lever

See what happens to the rear wheel.
Venkat Shyam,BV
Motorep
Bangalore

Auto Service
Bangalore
Email :v.v.shyam@gmail.com
IIMB mail :venkat.shyambv@alumni.iimb.ernet.in
(M): +91 9243 00 3337

#8 avinrichards

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Posted 16 June 2010 - 06:18 PM

UPDATE:

I did the above mentioned steps.

The rear wheel starts to spin the moment i engage the gear.

Also since the last 2 days ,when i thumb the starter in gear with the clutch depressed the bike jerks forward.

#9 devils doom

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Posted 17 June 2010 - 05:51 PM

open your clutch case, in the left bottom corner inside u will see a spring, its the gear shifter tension spring, if ur gears are going too hard then the spring have broken or the last time u changed ur clutch plates ur mech might not have fixed it, or it will be there and its tension might have gone, or if all this is correct then simply it the engine oil problem, which oil do u put ?, try putting shell helix all the mis-shifts, fasle neutral gear and hard shifting will go away...

Regards,
Devils Doom-

#10 v.v.shyam

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Posted 18 June 2010 - 04:43 PM

avinrichards said:

UPDATE:

I did the above mentioned steps.

The rear wheel starts to spin the moment i engage the gear.

Also since the last 2 days ,when i thumb the starter in gear with the clutch depressed the bike jerks forward.

The indications are simple.

There is a clutch drag. It needs to be examined after disassembly of the clutch & if necessary the plates need to be replaced.
Venkat Shyam,BV
Motorep
Bangalore

Auto Service
Bangalore
Email :v.v.shyam@gmail.com
IIMB mail :venkat.shyambv@alumni.iimb.ernet.in
(M): +91 9243 00 3337

#11 avinrichards

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Posted 18 June 2010 - 07:07 PM

ok sir. Will head on to your place soon. :rolleyes:




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