Question about Suzuki RM 125 Motorcycles

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Having trouble getting the gears to select down

I split the crank case to remove the crank 4 repair whilst split i must of moved the selector some how now it goes up threw all gears just doesnt wanna come down easy

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Since the shifting was okay prior to splitting the cas, chances are one or both of the positioning pins fell out. If this happened, the cases are not lined up correctly.

having trouble getting the gears to select down - 6de6a23.png

Posted on Aug 01, 2009

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I don't know what has not been removed so pardon me if I suggest something already removed. Remove the cylinder, intake manifold, magneto, stator, sprocket and shift lever. A case splitter is highly recommended. They don't cost that much and it makes for a clean separation. The two positioning guides will tend to hamper separation as will the crankshaft and output shaft as they slide through the bearings. That's another reason for a case splitter. Now would be a good time for new crank and output shaft bearings and seals and a new shift shaft seal. I assume the reason for the teardown is either a bent shift fork or broken gear teeth. If replacing a gear with a broken tooth or two, also replace any gears the broken gear meshes with. If you don't, you will get to do the gear repair a second time very soon after the first ride. Whatever pressure broke the teeth on one gear was also present on the meshing gear. It may look good, but it isn't. Please take a moment to rate my answer. Thanks.
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You have an internal problem with the shift mechanism.You will need to remove the clutch cover to identify what is broken.It is rare that you can't fix a problem such as this from behind the clutch cover.(ie no need to split the crankcase).pull of the clutch cover & look to see if when you try to select gears if the selector drum turns. It should then be apperent what has gone wrong.(circlip fallen off,selector drum actuator or spring broken)
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The motor comes out of the bike then turned upside down for removal of the bottom case. The clutch, shift shaft, flywheel, electrics, gears and gear shafts gotta come out so you can get to the bad fork. There's much more but the idea is that you are better off having the shop do the repair unless you have experience, are extremely mechanically inclined, and have the tools. The bad news is that a shop is going to charge around $1200 to $1500 for the repair. Some shop mechanics also repair bikes at home. If you find one, you can save $200 to $400 or so. Sorry to be the one to give you the bad news. The diagram below shows how a shift fork moves a slider gear left and right to engage different gears. A bent fork will not fully engage a gear.

A “very helpful” rating on this answer? Thanks!

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