Shift Star replacement

[Johno]

Hey, not sure if this is the correct forum to be posting in. Sorry if it isnt.

I have a Lifan 140 and am in need of a replacement shift star, as far as I know the stock stars that come with these bikes are well crap.. and I believe that is the cause for my bike popping into neutral. So I'm after an aftermarket star that will fit, like SDG.

PROBLEM.

The problem is I live in Australia and cant seem to find anyone selling the stars, I've looked on eBay and shops like Thumpster and Braaaap... nothing..... does anyone know of a place that sells stars that ships to Australia??

 

[motodevo]

I assume you have pulled off the clutch cover and checked it first, if not do so because it may just be the shift star screw has backed out, it will give similar symptoms and is more common, a dab of red loctite will stop it coming out again if it has, or a bent shift arm, i cant stress enough if you havent had a look yet do it and move the lever while watching it (may need to turn the output shaft while doing it to ensure the gears engage properly)

 

[Johno]

I assume you have pulled off the clutch cover and checked it first, if not do so because it may just be the shift star screw has backed out, it will give similar symptoms and is more common, a dab of red loctite will stop it coming out again if it has, or a bent shift arm, i cant stress enough if you havent had a look yet do it and move the lever while watching it (may need to turn the output shaft while doing it to ensure the gears engage properly)

Yeah Ive pulled it apart and taken the clutch out.
The star was seated correctly, I used the gearshift level on the bike to see if anything was out of the ordinary and all I could see was the arm moving by the star no spinning everytime, it would like sometimes catch it and othertimes the arm would move and the star would still remain seated

 

[zwebx]

Yeah Ive pulled it apart and taken the clutch out.
The star was seated correctly, I used the gearshift level on the bike to see if anything was out of the ordinary and all I could see was the arm moving by the star no spinning everytime, it would like sometimes catch it and othertimes the arm would move and the star would still remain seated

according to the links mx67xr posted in your other thread you can deremel out the bottom of each side of the shift star to make it bite better

 

[Johno]

according to the links mx67xr posted in your other thread you can deremel out the bottom of each side of the shift star to make it bite better

I was just playing those parts, it seems the reason the little circle thing (not sure what its called) isnt sliding all the way into the stars groove is because the shift arm isnt pulling the worm gear the whole way across?? It doesnt appear that the shift arm is bent so Im thinking that something is either jammed in the transmission; broken teeth or something bent in there.

Its almost as if the shift arm isnt long enough to grab the next worm?

I will post a vid

 

[zwebx]

i would like to see the video, i would have to see if its the shift drum not moving enough or if its just not deep enough star to make it hold

 

[Johno]

i would like to see the video, i would have to see if its the shift drum not moving enough or if its just not deep enough star to make it hold

First vid: without star on, so you can see the worms
http://www.youtube.com/watch?v=75snt-HSBqU

Second vid: with star on,
http://www.youtube.com/watch?v=FdXsWDaVSZQ

 

[zwebx]

Maybe its that top spring on the top of the mechanism?
good thing you did not split the cases

 

[Johno]

Maybe its that top spring on the top of the mechanism?
good thing you did not split the cases

Yeah I dont want to unless I have to... Knowing me I wont be able to get it back together haha.

So the spring highlighted in orange is what? To loose maybe? Worth getting a new thing altogether? (highlighted in green).

 

[zwebx]

yeah i reckon that one maybe try it with a little more pressure towards the top of the motor with your hand? also is that bolt on the bottom tight enough? it does look like it may not be moving far enough
also how many hrs approx is this engine at?

 

[my67xr]

it could still be the shift forks on the gear drum are worn.

i have another video link, this will help get rid of some movement/slop
.
http://www.miniriders.com/videos/38...-but-should-work-most-horizontal-engines.html

 

[Johno]

Bike has between 10-15 hours.

No loose bolts, I think worn shift forks because it just doesnt want to spin the entire way around. Split here we come.

 

[my67xr]

have you tried changing gears while turning the sprocket (turning the rear wheel),
and watching what happens at the shift star?

 

[Johno]

have you tried changing gears while turning the sprocket (turning the rear wheel),
and watching what happens at the shift star?

Yeah, sometimes it will change and sit nicely in the star's groove. Then other times it will sit on the tip of the star.

When I say "it" I mean the yellow highlighted part, sorry I'm not sure the name of it.

 

[motodevo]

Could just make a new shift star if SDG can't/won't reply to emails

 

[Johno]

How do I remove this clip (red highlight) to get the gear off, I need to tighten the allen key in behind (yellow)

 

[zwebx]

maybe a large screwdriver or circlip pliers are the way to go anything that can spread stuff with considerable force (putting your hand over it so it does not fly away)

 

[my67xr]

http://www.supercheapauto.com.au/on...-Bent-7-.aspx?pid=168020&menuFrom=70301#Cross