160 demon dxr gear box problem

[gordonhooper]

can any1 help me my 160cc demon dxr 160 is really hard to put in gear an when it gets into gear it slips out sometimes

 

[my67xr]

welcome to miniriders,

is your shift lever adjusted to suit your footing position?

 

[my67xr]

otherwise it may need some tweaking in the gearbox area,
http://www.scribd.com/doc/45909086/Fixing-Gearbox-Issues
http://www.scribd.com/doc/45931259/Daytona-125cc-repairing-locating-arm-gearshift-fix-2
or check the locking bolt for the shift drum is tight,
it is found just above the front sprocket, behind/underneath the rubber plug.

 

[gordonhooper]

yer the positions fine mate and so is the bolt :-/

 

[my67xr]

is the clutch cable adjusted correctly?

otherwise it sounds like it is a clutch cover/clutch off job then?

 

[gordonhooper]

erm i dnt kn mate how can ya rell if its on correctly thanks for the help by the way

 

[my67xr]

is the adjuster at the clutch lever, screwed right out or screwed into the handle?
can you squeeze the clutch lever a little, without feeling the clutch moving,
there needs to be a little freeplay there.

 

[my67xr]

also is it doing it in all gear positions, N, 1, 2, 3, 4 ?
or does it just jump out of 3rd gear, for example.

 

[gordonhooper]

erm i dnt kn mate how can ya rell if its on correctly thanks for the help by the way

 

[gordonhooper]

yer it slips out of all gears an its really hard to put in all gears

 

[my67xr]

it's only a guess,
but id think you'll need to take the clutch cover off, then the clutch and check out what is happening.
everything is pretty much covered in the 1st link (post #3) i posted above

 

[GooseMan]

Hey never knew about that, I think i'll give it a go on my ds80.

 

[my67xr]

is the DS80 doing the same thing?
mates RM80 (basically same motor/gearbox as the DS) had that problem too, ended up being twisted arm from the shifter rod to the shift star.

 

[rotn50]

Sounds like the selector star tensioning rod has skipped up and is sitting on the side of the selector star, This is just gibberish to you mate, but maybe the clutch case needs to come off and the selector area needs inspecting.

 

[gordonhooper]

i can pull the clutch in but its harder than normal lol

 

[gordonhooper]

the cable doesnyt have any movement or freeplay mate and when i put it in gear it dindnt do anything i had to lift it agen to get it to even do anything

 

[rotn50]

Your clutch lever will feel tight and very hard to pull in if the clutch nut comes loose.

 

[gordonhooper]

its not really hard its like abita both tbh lol