kurtas

If you can't get ELF HTX740 then GRO TRANS EXTREM 75W is the go for the transmission oil from my experience, never had an issue with either.

When you pull the clutch lever in I assume you can feel the mechanism trying to activate the clutch? Also I assume you have tried riding it in a high gear with the clutch pulled in while accelerating?

On my gasgas enduro bike I went to the shop and bought a cheap ring spanner and ground the outside down until it fit. Scientific torque spec I used was almost as tight as I could do it by hand and then give the the spanner a couple of light hits with a hammer.

Trials bikes are normally fairly difficult to change into neutral, I normally just turn my bike off then put it into neutral. On the odd occasion you can knock it into neutral with it running but its certainly not really easy.

GasGas had the same forks at the time, so you could look at them also.

From memory the suspension was the same between the trials and the explorer variant. Marzocchi forks and Ohlins rear shock.

I would start by lining it up with the other bearings in the case. it may be a shim that was added to get the correct end float on a shaft.

https://www.trialsbike.com.au/product/ossa-5020040211-air-filter-box-lid/ Was an Ossa dealer at the time, so he may still have a stand if you send him an email.

TY, DT, GT MX80's all have very similar parts, so if you can find a wreckers etc they might have parts for one or all.

Another thought, you could see if a sleeve was available for the seal area. Then just give the bearing area a light cleanup with emery. https://www.skf.com/au/products/industrial-seals/power-transmission-seals/wear-sleeves/skf-speedi-sleeve

You could investigate getting the damaged areas chrome plated. They would grind the part down and then chrome plate back to size, hopefully removing the damage in the process. The seal area is the key, I don't think it would matter if there were a few surface defects like what you've got where the bearing sits. If the depth of the defects are less than 0.25mm than it should be acceptable to chrome plate.

Have you checked the HT coil, spark plug and lead? Not sure but it wouldn't surprise me if the electronic ignition kit for an SWM would fit. https://www.motoswm.co.uk/shop/swm-rotax-trials-electronic-ignition-kit-pro/

The spring/open side faces inward so that when pressure is applied from the compression of the fuel mix in the bottom end it energises the seal. If it is the other way around only the spring/material strength is what is creating the seal which should be enough to keep out the air or gearbox oil which is not under a relatively high pressure.

Plus one to Jonnyc21, has been crushed in shipping, the split is normal though. You might be able to buy the bush from a local engineering/bearing supplies store or online rather than getting Honda parts if it is not a special size. It is a glacier bush, very common part.

If you want a competitive trials bike the TY. if you want to have a nice trail bike which also goes through trials sections the TL.