9 replies to this topic

[JohnH]

Just stripped the engine down to find out what is causing it to drop out of first gear when not under load and found the above.

So I have a couple of questions:
1. Is it worth the time/risk trying repair?
2. Are clutch bosses still available?

Also, are any of the 125/200 engine parts interchangeable?

Cheers

John

[bilc0]

Crikey 3 missing, They screw in so you may be able to find someone to machine some up for you.

[Lee Harris]

par for the course....


normally you can use the old ones---or are they bu%&er$d? Getting new ones turned is easy. Make the threads a little longer, say plus 1 mm and swage them over on the back...you must remove the hub first. If you have the old ones the swaging will have broken off...look for the metal bits and take them out...otherwise they will swim around in the gearbox which isnt good. I use the old ones and use permanent loctite. new ones (hubs) are not available, one on evil bay at the moment. i THINK 125 and 156 are the same

HTH

[Lee Harris]

http://www.ebay.co.u...=item4161bcdf1e

[JohnH]

Thanks for the replies,

Quote

Crikey 3 missing, They screw in so you may be able to find someone to machine some up for you

I would never have guessed that, wonder what their thinking was when they decided to do that? Maybe they knew ham fisted home mechanics like me would get our hands on it so they designed it to be easily repaired!!!!

Quote

normally you can use the old ones---or are they bu%&er$d? Getting new ones turned is easy. Make the threads a little longer, say plus 1 mm and swage them over on the back...you must remove the hub first. If you have the old ones the swaging will have broken off...look for the metal bits and take them out...otherwise they will swim around in the gearbox which isnt good. I use the old ones and use permanent loctite. new ones (hubs) are not available, one on evil bay at the moment. i THINK 125 and 156 are the same

I have the old ones and know a decent enineer so will ask him to make me some new ones. Thanks for the link to ebay I might bid on that to see if they do fit. That chap also has the gearbox internals which might cure the original problem as well.

I did find a few bits of metal (see pic below) and was a little concerned about where they had come from, I thought they might have come from the lock tab which was a bit butchered.

[Lee Harris]

JohnH, on 30 January 2012 - 10:55 PM, said:

Thanks for the replies,


I would never have guessed that, wonder what their thinking was when they decided to do that? Maybe they knew ham fisted home mechanics like me would get our hands on it so they designed it to be easily repaired!!!!


I have the old ones and know a decent enineer so will ask him to make me some new ones. Thanks for the link to ebay I might bid on that to see if they do fit. That chap also has the gearbox internals which might cure the original problem as well.

I did find a few bits of metal (see pic below) and was a little concerned about where they had come from, I thought they might have come from the lock tab which was a bit butchered.

Remember that 125 and 156 gears are not the same

[JohnH]

Quote

Remember that 125 and 156 gears are not the same

Thanks, I will just go for the clutch then.

[furse]

Looking at the picture, has the clutch plates been rubbing on the basket rivits?

[furse]

Lee, Which gears are different?

Edited by furse, 31 January 2012 - 06:39 PM.

[Lee Harris]

1st and second. Thats why 125s came with 11/53 and 156 ran 11/51 as std. The 156 gears are lower