help needed finding problem on cr125 transmission

Juan Jaramillo

So I finally open up my cases and found the main shaft fork with sone damage and the c1 bushing on countershaft does not want to come apart. The one on c1 33t

The problem I had at mid Ohio was that transmission was doing a neutral in 5th gearduring on of the practices. After inspecting the engine I went out again for the last race and after 1.5 laps with the same problem, the engine got stocked doing light damage to cilinder and piston.Temp was 132 at the time.Any help is highly appreciated.

I found this on main shaft fork

This bushing doesn't want to come out

This fork shaft wiggles in this side of the case (is this normal?)
if not, is the case bad or the shaft?

There is some rounded dogs on the 23t main shaft gear, can this be the case of having a neutral in 5th?

Also, why are these dogs different in size? one is thinner than the other one.,

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Jeff DeMello · Posted: Tue Jun 28, 2011 11:18 pm Post subject:

What his kart did was shift thru 1-4 gear with no problems then when it was shifted into 5th the engine would lock up and stop running. This was on the kart stand. It would shift thru all 6 gears not running.
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Jeff DeMello
Emmick F125 Pavesi

Mike Pham · Posted: Wed Jun 29, 2011 2:47 am Post subject:

Check for excessive play in the countershaft, I had a similar issue of a false neutral on the 5-6 shift and it ended up having too much play on the countershaft. I had similar wear inside the trans as well, ended up replacing those components too.
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Juan Jaramillo · Posted: Wed Jun 29, 2011 1:21 pm Post subject:

how many times should the drum click when done manually?
or how many positions? should be six?
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Juan Jaramillo · Posted: Thu Jun 30, 2011 6:30 pm Post subject:

Seriously, that's it? Not even a Mike Goebel's post Smile

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Mike Goebel · Posted: Thu Jun 30, 2011 6:43 pm Post subject:

Please send entire engine to mfg Tech Centre for a free examination and labor free repair.

Mike G.

Eric Clements · Posted: Fri Jul 01, 2011 9:34 am Post subject:

Mike Goebel · Posted: Fri Jul 01, 2011 12:17 pm Post subject:

The dogs are too worn that's why it's slipping out of 5th. It's a common occurance.

Mike G.

Noah Stark · Posted: Fri Jul 01, 2011 12:59 pm Post subject:

It only slipped out of 5th once or twice. Every other time it locks up in 5th gear only when engine is running. I had it apart twice and everything is where it should be. That fork was brand new and those marks are from only a few mins of track time. The only thing I can think of is the cases arent from the same year or one is warped a good bit to where the fork shaft on the secondary side isnt square to the tranny shafts, making it bind when put into gear. However, it shifts fine with the cases split and with the motor not running. This only happens when the motor is running, either on track or on the stand. I had 6 different people come over and inspect the tranny and my re-assembly of it before I put it back together at mid-ohio. Everyone confirmed they saw nothing wrong and all the correct parts were in the correct places. I had people with more than twice my 20yrs in doing engines stumped. Trust me, this isnt a issue of what oil, or is this washer supposed to be here.

Honestly, if I would not of seen the motor do what it did myself, I wouldnt of believed Juan after I tore it down. This issue has numerous people scratching their heads, including me.
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Noah Stark
RIP my friend:Paul Dana you will be missed by many

JT Miles · Posted: Fri Jul 01, 2011 1:47 pm Post subject:

...
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Mike Pham · Posted: Sat Jul 02, 2011 4:55 am Post subject:

Is this a brand new setup? If not what year cases/what year gearbox? I know there was a change in lengths of the countershaft and which is why I asked to check the play, I thought I read somewhere Honda changed the countershaft length or main shaft spacing after a particular year?
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Jeff DeMello · Posted: Sat Jul 02, 2011 5:31 am Post subject:

Jaun bought this engine from someone in Col. he put it on his kart and it would not start and found the tranny all messed up. The guy he bought it from sold him a junk motor from the start. it was rebuilt but still has the tranny problem. Beware of what you buy on line.
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Jeff DeMello
Emmick F125 Pavesi

Anthony Iuzzo · Posted: Sat Jul 02, 2011 10:26 am Post subject:

its not the countershaft that changed in length from early 90-94 CR's it is the mainshaft......I went through a similar problem recently......the proper 96'-97' mainshaft is slightly longer than earlier shafts, compare the mainshaft you have with a known 96'-97' shaft, it may be the problem

frank rapisarda · Posted: Sun Jul 03, 2011 9:48 am Post subject: juan jaramillo

Juan, Noah is on the right track i have bin doing transmissions for 20 + years, honda is the only one that does not give the dimensions of the washers in the transmission. If someone besides you had it apart before, they may of dropped a washer an put it back in the wrong place. I owned a bike shop for years and now i am into karting. I always had people bring in a bucket full of parts to a trans for the same problem as you and yes it will shift when it is apart. i would bring it to a good bike shop close to you, you will save in the long run.
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Juan Jaramillo · Posted: Wed Jul 06, 2011 7:39 am Post subject: