Gear Selector Centreing Spring Broken

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Gear Selector Centreing Spring Broken

Postby Shiny » Sun Mar 06, 2016 4:02 pm

My 2005 MZ1000ST has broken spring. Can I assume this is a part common to other makes? Any help appreciated. Unfortunately the broken off part appears to have dropped into the sump so, until I retrieve it I cannot determine the style.
Shiny
 
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Re: Gear Selector Centreing Spring Broken

Postby Shiny » Sun Mar 06, 2016 9:36 pm

Thanks for the link to the parts book. I'm having a local spring manufacturer make up 2. They will be a bigger guage so should last (bike has 47,000 klms).
If anyone needs one I can supply.
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Re: Gear Selector Centreing Spring Broken

Postby MJ310 » Sat Mar 12, 2016 12:36 pm

Mine has gone as well, seems to be a common fault, bike works fine and I can select gears but I have to be slow and deliberate. One day I will open it up and have a look. Take a picture and post it.
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Re: Gear Selector Centreing Spring Broken

Postby Shiny » Sun Mar 13, 2016 2:54 pm

MZ Spring.pdf
Gear Selector Centreing Spring
(102.7 KiB) Downloaded 461 times
Hi MJ,

Graham's confirm they have these in stock for a very reasonable 6 - 7 pounds. A huge saving on the $350 my local spring manufacturer wanted.

Here's the part you need;
33 3547306000 Rückholfeder für
Schaltwelle
return spring for shifter.



I found the broken piece in the sump. Tried retrieving through the sump plug hole with a magnet but missed it. Ended up removing the sump (Radiators and exhaust need to come off) which revealed absolutely no metallic material or sludge at all. Nice to know.

To get at the mechanism you need to remove the clutch. I made a special tool from a socket and used a rattle gun to remove the clutch nut/collar.
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Re: Gear Selector Centreing Spring Broken

Postby boilermaker » Tue Mar 15, 2016 7:00 am

My gear return spring also broke at around 30,000 m. Grahams supplied a new one and I made up a clutch tool from an old socket. Thank god the selector operating system is outside the gearbox. Although the box on this machine can be removed in one piece if I remember rightly.
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Re: Gear Selector Centreing Spring Broken

Postby MJ310 » Fri Mar 18, 2016 3:05 pm

Can you tell me what you did to make the clutch tool or show a picture, I will buy a spring next time I am in Taunton.
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Re: Gear Selector Centreing Spring Broken

Postby Shiny » Fri Mar 18, 2016 5:30 pm

33mm I'd is a critical measurement. Used a grinder and a miniature belt sander followed by hand file to finish. Hope this helps.
Attachments
IMG_20160319_112234.jpg
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Re: Gear Selector Centreing Spring Broken

Postby MJ310 » Sat Mar 19, 2016 2:20 am

Thanks Shiny, I don't have access to a grinder at the moment but I might know someone who has. How thick are the teeth?
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Re: Gear Selector Centreing Spring Broken

Postby DAVID THOMPSON » Sat Mar 19, 2016 7:08 pm

grind it slow so you do not get too hot and ruin the temper

dave
Dave 2002 MZ RT125+1995 Saxon Tour(500cc)
1997 MZ 660 Traveller+6/13/09 WV USA
"IN the end times the IDIOTS will be in charge
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Re: Gear Selector Centreing Spring Broken

Postby Shiny » Sat Mar 19, 2016 7:29 pm

The posts are approx 5mm wide with approx 20mm between them. Davids right, too much heat might result in the dogs failing due to the rapid power delivered by the rattle gun. It really is worth taking your time, trial fitting as you go.
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Re: Gear Selector Centreing Spring Broken

Postby billr » Mon Mar 21, 2016 6:07 pm

That looks amazingly like a bicycle tool I used to have...don't have that bike any longer( and no idea where the tool wound up...it ain't in the box)

Park 4-prong freewheel tool
That one is only 32mm inside diameter, though.

BillR
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Re: Gear Selector Centreing Spring Broken

Postby Shiny » Thu Mar 24, 2016 11:20 pm

I've been reassembling the clutch following installation of the new gear selector centering spring. I've found that after doing up the centre clutch nut with the rattle gun, it's locked with the basket. On taking some pressure off by slightly unwinding the nut it free's the basket but still is binding.

Went ahead and assembled everything only to find the clutch lever is locked and not actuating the clutch release rod.

Anyone have any ideas? I didn't lock the clutch lever to the handlebar as I didn't think it nessecary.

Not a good day at the office, still great riding weather, so leaving it for the night.

Appreciate any advice.
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Re: Gear Selector Centreing Spring Broken

Postby Shiny » Thu Apr 14, 2016 9:51 pm

Ha! that old extra thin gear behind the main cog driving the clutch not aligned trick.

I don't have the special tool shown in the manual so carefully used a screwdriver to move it into line.

Not sure if this will work as I don't understand the purpose of this thin gear.

Can anyone enlighten me?
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Re: Gear Selector Centreing Spring Broken

Postby MJ310 » Fri Apr 15, 2016 3:03 am

Can't help I'm afraid but it's all useful stuff for when I tackle mine. Keep us informed on what you find.
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Re: Gear Selector Centreing Spring Broken

Postby Shiny » Sun Aug 28, 2016 8:57 pm

Well, after all the nervous-nous around the pretensioned gear behind the clutch cog, the bikes running fine. What a difference a new set of spark plugs has made.
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