November 20, 200520 yr Anyone out there have any experience of or know of problems with gearbox on TLR250 Hondas which causes the gearchange to be very stiff and hard to change gear. I was thinking along the lines of possibly a bent selector fork but if anyone knows any better I would like to hear any suggestions. As you know its a total engine strip down to access the gearbox hence I an still toying with the idea of leaving alone since otherwise the motor is very good - but if there is a weakness I dont know about then I am as well to strip it down and fix it.
November 21, 200520 yr Hi Gordon, Have a few probs with mine as well but could find nothing at stripdown earlier in the year, I did some asking around as well. Like you the engine is now so strong that I don't want to alter this by stripping the whole engine again regards Donald
December 11, 200520 yr Author Seems as if I have solved my gearbox problem. Initially I thought one of two things, a bent selector/selector shaft or a 'tight' selector drum. I thought that the selector was less likely since the problem was not related to only one or two gears but all six. After stripping the motor and examining the gearbox very carefully (as I did when I built it a year ago) I could not find any signs of selector problems BUT it was clear that the selector drum had been rubbing on the casing. I tried building the casing with the gear cluster and drum alone and it was clear that the drum was the root of mu problems. There are two options - make a thicker gasket(or use multiple gaskets) or turn some metal offthe end of the drum in a lathe. I chose the former, deciding on a gasket thickness after careful experimentation - et voila as our French friends would say, an easy gearchange again. Just think the bliss of being able to change gear in a section - perhaps my scores will mysteriously drop - then again pigs might fly....... If anyone else is using an aftermarket gasket set they may end up with a similar problem since the gasket is likely to be a different thickness than the OEM (Unobtanium!)Honda one, try putting the gearcluster in the cases and tightening the cases up to see if you have clearance before you fully build the engine it might save some grief in the long run. A thin gasket probably did not help my gearchange although I am not convinced it was the sole cause. Gordon
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