Gearbox problem (hard clunks when downshifting)

[RS_Patrick]

If you put iot back together it needs to be about 0.5mm, but if your just checking the engine before doing a rebuild or just a maintanance check and its more than 1mm you have to do something about it.

The steel plates got a notch on it, they need to be ofsed 120 degreas from each other.

Clunks downshifting can be from a number of things, but the most common one i come accross is the clutch not being adjusted properly or a problem with the plates/basket so it does not fully disengage wen pulling the lever in.

[Gabriel95]

Thanks for help very much Patrick, and how about the 2 cranckcase halves is pretty simple to put them back together or do i need to know something (does the bearing fits easily on the cranck?)

[RS_Patrick]

Sometimes they fit easly onto the crank and sometimes they dont :P:

The crankcases should come together pretty simple, should say in the manual how to tighten them up one by one and little by liitle, so tighten them up evenly in opossing order.

After there together you fit the seals, pay close atension to the right hand side crankseal, as theres an outher normal seal and an o-ring internaly under the bushing that goes there.

[Gabriel95]

Patrick, do you mean that you can simply put the left crankcase half on the right one till theres a sertai gap left( cant push it down anymore) and enclose the case by tightening case bolts in a patern?

[Gabriel95]

Any other way to put the crankcases together without a special tool as shown in manual?

[RS_Patrick]

Yeah, just put them together and gently tap with a plastic hamer and tighten up the bolts in the patern described.

Make damn sure all the shafts etc. are in the bearings hole there ment to go into.

[Gabriel95]

Got it, thanks for help a lot