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Hello. So, I purchased a torn down 78 DT175 and rebuilt it top end to transmission. It had needed a new shift shaft which I replaced, and put it all back together and got it running! I was so proud it was going finally after all that effort. However, it wasn't shifting properly, and I am hoping someone has knowledge on this specific issue.
So in order to shift it you have to kind of jimmy it; for example on the shift up, the shifter would stay up and I'd have to tap it back down before I could shift it up again to the next gear, and visa versa shifting down. So, I currently have it all back apart to assess the issue.
Upon inspecting all the springs and mechanisms per the repair manual, I don't really see any issues; all the springs look good and are properly connected. But, if you look at the images, in the manual at 18. "Shift the transmission into 1st gear. The index mark on the shift cam and upper shift arm must align for a proper shift progression from gear to gear. " As you can see, mine is not aligned, however, I am in NEUTAL at this point, and so HOW DO YOU SHIFT INTO FIRST when at this point per the manual the shift shaft is removed? Or, is my alignment good because this is where it should be when in neutral?
I don't see how it could be off anyway as I have never removed the shift arm before and was told it ran fine before it was taken all apart.
Also, before I reinsert the shift shaft, should I grease it up? If so, what type would you recommend?
Any other advice as to why it is not shifting right?
Thank you!!
I had sent a private message thru email. I guess it didn't go thru.
"Hi Dave,
Just wanted to give you an update regarding this fix. It has been quite a long process as I only have weekends. First off, I got the clutch grabbit tool, and was quickly able to get the clutch back together. That thing works great and I wish I had it a long time ago! Then, the last time I had this thing apart, I didn't get the clutch properly adjusted, as it didn't have that step called out in the manual, to reference back to such and so page for push-rod clutch adjustment. Well, so I got that figured out this time around. I got that far, and needed some formagasket as I couldn't find any at home. So I had to pause there till I could get some.
Anyway, I was cleaning the gasket surface, and going to put on the cover, I saw an e-clip in my parts area, and realized, after much re-reading thru the manual, that it must go onto the shifter arm behind the clutch basket. I must have missed it as I was in between weekends at this step. So, I go to remove the clutch basket all over again. Got the e-clip on the shifter arm, put the clutch basket back together, re-adjusted the push rod, and went to tighten the clutch spring bolts to spec (60in/lb).... and the bolt sheared off! So, it is quite a small hole, didn't have a tap that was small enough diameter to pull it out, ended up slightly damaging some threads on the clutch boss trying to drill it out, but, the bolt still goes in. So I need to find a new bolt now. I feel these bolts are really thin diameter to be tightened to 60in/lb.... I was tightening the bolts slowly in a cross pattern from each other, this happened to me in the past. I feel this is too tight.
Another question I have is when installing the clutch basket, do you tension down the clutch spring bolts FIRST and then adjust the pushrod? or is it visa versa?
Thanks"
Welcome to the site!
Post #2
Once you have it in 1st gear . . . remove the shifter "arm" by taking the retaining C-clip off.
This will allow you to get at the lock washer tab (16), and lock nut (15), that prevents the eccentric adjusting screw (14) from turning. Once the screw is loose, you can reinstall the complete shifter set-up. Make sure you have the small shifter shaft roller (7) installed . . . . this is a critical part.
Once installed, you can adjust the shifter arm by turning the screw in or out, which in turn, moves the upper arm either to the right or to the left. Generally speaking, you're aiming to center the arm's "catch hooks" evenly, or centered on either side of the shift cam pins. Adjust the alignment marks as needed, or until it seems to fully engage each gear correctly. Then remove the shift arm and lock down the adjusting screw nut and washer tab. Reinstall everything and test once more before installing clutch and cover.
Note: Some gear changes may seem hard to shift when the engine is static (not moving).
You may have to turn the countershaft sprocket to complete some of the shifts.
Hope this helps, but if not, we'll keep discussing it until it's fixed.
Study picture below.
Post #1
Hello Gemstone, and welcome to the forum !
The blue bike pictured in your profile picture appears to be either a 80 or 81 model.
I wonder if this is the bike we are discussing, or do you also have a 78 model as well ?
1st, you are correct that the arrow and mark should align when it's in 1st gear.
You should be able to get it into 1st gear (instead of neutral), by sticking a small screwdriver through the shift cam pins, and rotating the cam counterclockwise . . . . you may also have to rotate the countershaft sprocket to complete the shift.
Please see where I'm pointing in photo below.