84 Honda ATC 125M pops out of gear

[Ryan01228]

Hey folks..New to the Forum and fairly new to non-automobiles! I have had a couple motorcycles and this is my second ATC.

Anyway, just bought a 1984 125M and I really like it...The ONLY issue I have is that it will "pop" out of gear pretty regularily especially when its cold.. It feels like the bike has gone back to neutral but the nuetral light does not come on. Also often I can get it to "lock" back into a gear by going up or down with the shifter.....

So my questions are...
Is this common?

Could this be due to a clutch adjustment?

Where should I begin to check it out?

[fabiodriven]

The problem more than likely isn't going to be with the clutch, it's probably in the transmission. More than likely you're going to have to tear into it and find out what's wrong, but there is something you can try before you go that far.

When was the last time the oil was changed? If it's been a while you may just need to change the oil. Make sure you use the proper oil that is compatible with a wet clutch setup. I would recommend either a synthetic or a synthetic blend. I have had tranny issues with 110's (almost the same motor) in the past with them sticking in gear. All it took was a simple oil change to cure it. I can't promise this will fox your problem, but it's a good place to start. Good luck and :welcome:

[mrcribbs]

Take your clutch cover off and inspect. Usually it's this part that breaks...

http://www.dratv.com/268n.html

[Ryan01228]

Thinking I will do both....

I am guessing I have to remove the oil before removing the clutch cover anyway?

Ok...So the clutch cover is the inspection panel on the right side? or Left?

[rdlsz24]

Yeah drain the oil first. The clutch cover is the whole cover on the right side. Held on by 10 little bolts or so.

I had a 125m that had tranny problems as well. It was stuck between gears and I found eventually that 3rd gear was shot. http://www.3wheelerworld.com/showthread.php?85808-125m-transmission-woes-video-inside&highlight=

Rob

[Ryan01228]

ok..well looks like I have my weekend project...Thanks for the quick responses folks..I will let you know what I discover..

[hang&rattle]

Please post what you find, my daughters 85' does the same thing. I changed the oil (use honda oil) a couple of days ago, haven't had it rode yet, but feel the problem is possible deeper than that.

[shortline10]

Yep did one of those yesterday . Could also be a bent shifter fork but lets hope not .


Take your clutch cover off and inspect. Usually it's this part that breaks...

http://www.dratv.com/268n.html

[Dirtcrasher]

9 out of 10 times it's something to do with what locks the shift drum in any particular gear. If it's any gear at any given time, it isn't usually a bent shift fork, rather an external issue (meaning the linkages, posts, springs, pawls etc etc) found beyond the center case. Not everyone enjoys splitting cases.

Most split cases end up in a 5 gallon bucket or a box, only to be wasted away..............

[shortline10]

Quote : by dirtcrasher Most split cases end up in a 5 gallon bucket or a box, only to be wasted away.............. Quote
So true and sad:beer

[Xpress]

I think you should change the oil before you do anything. I like to use 10W-30 in all of my machines, but mainly because I'm in California, and it doesn't get too cold here (comparing to other parts of the country).

With my 110, it just refused to shift into 4th all together, and when i split the engine apart, I found out my 4th gear had a pin broken off of it, which looks like is what engages the gear.


Most split cases end up in a 5 gallon bucket or a box, only to be wasted away..............

So true. My 110 engine is in a thousand pieces in my basement, and I'm fighting to keep it from going into the 5 gallon bucket of no return :(

[tri again]

so is it ONE gear in particular?

or does it want to slip into neutral in any gear and then grab and lock in if you up or downshift?

A sloppy external shifter MAY not be giving you full throw until you get aggravated and actually sorta stomp on it but since you have another trike, you're prob used to how they should feel.

I'd drain the oil onto a screen and change it anyway, but keep us posted.

[factoryX]

Most split cases end up in a 5 gallon bucket or a box, only to be wasted away..............
LOL, my 110 motor is apart in a box in the corner of the garage.

[hdeuce]

weekend project pshhh.... tip the bike on its left side, remove the clutch cover. You can remove the stopper pawl without removing any other part. No need to drain the oil either. I have done 3 this way.

[zppeacock]

I had one that popped out of gear randomly mostly under heavy acceleration. I ended up selling before I fixed it.

[Ryan01228]

I pulled it apart just now..Everything looks to be ok...Although putting it back together appears to be a pain...Still not sure which item ithe the stopper paw...I am going to reassemble...Use the honda fluid I bought and see what happens...

[shortline10]

Does it fall out of gear while riding or is it more of a shift problem were it goes into neutral while it should be in a gear .

[tri again]

x2 agree w' shoreline 10.

can you remember a little more specifics about the shifting and popping?

is it one gear or all, sometimes?
on the gas or decelleration?

or just sort of floating at an easy constant speed... that kinda info would help

[Ryan01228]

All is well!

Works Great!

Is it OK to use RTV to seal the case, instead of a Gasket?

[Ryan01228]

There was a smal "bur" on the inside of the triangular piece withe the three bearings. I filed it down and cleaned it up, reassembled, filled it up with honda oil and adjusted the clutch. Runs, shifts and stays in gear now!

Was it ok to reassemble with RTV?

[tri again]

[QUOTE=Ryan01228;929861]There was a smal "bur" on the inside of the triangular piece withe the three bearings. I filed it down and cleaned it up, reassembled, filled it up with honda oil and adjusted the clutch. Runs, shifts and stays in gear now!

Was it ok to reassemble with RTV?[/QUOT


Some say BE CAREFUL and find rtv clumps blocking oil passages , say, to the head and camshaft. (terminal)

I think side cover gaskets are 10-15$.

When I use rtv, blue, I'll put it on super thin, glide my finger over it so it's thinner at the inside edge.

Lay on a gasket (if you have one) and put it face down on a clean surface to dry and hold the gasket in place,,so it will stay there if you ever have to take the cover off again.

if no gasket?

same tapered application of silicone, thinner towards the inside and thin in general.

I let it dry completely so it's like compressing a godbless'ed rubber band, torque each bolt a little at a time in opposite cross pattern and you will smile when you see an infinitesimal amount of sealer
thinking about squeezing out between the case and cover.

That will tell you that you have no engine killing globs trying to break off inside your engine.

A good clean workbench , good light and no distractions or cats jumping up and you'll be ok.

[firemanfires]

Hello. I have this issue with my 1985 honda 125m the indicator on the case shows it shifted but it sometimes does not shift into gear and i have to play with it to get it into gear. I have changed the oil and that has not worked. I have been told it is the fork and also the stopper pawl. Is there a way to determine what the problem is? Also to change the fork does this require splitting the case?

[shortline10]

Sounds like your shifter drum stopper broke . Easy fix , just pull the right side motor cover off and replace . here is the part you will need . http://www.dratv.com/268n.html



Hello. I have this issue with my 1985 honda 125m the indicator on the case shows it shifted but it sometimes does not shift into gear and i have to play with it to get it into gear. I have changed the oil and that has not worked. I have been told it is the fork and also the stopper pawl. Is there a way to determine what the problem is? Also to change the fork does this require splitting the case?

[Jason125m]

Mine did the same thing, there is a nob inside the clutch that got ground down over time. And eventuallky snapped right off.

[jamcc85]

what knob in the clutch are you refuring to

[jamcc85]

i also have a 85 125 m that is hard to get into gear and to down shift does anyone know what could be wrong with this. The shift indicator shows that it is shifting but when you give it gas it pops out or does not go in at all.