My Gasser Let Me Down Today!!

[singletracker]

The shifter is shot! I was on the first lap of a hare scramble today when it went totally limp. No crashes or contact with anything it just quit working. I tried to shift but the shifter was down against the frame. So I pulled up on it and it pulled up with no resistance what-so-ever. It goes all the way up until it hits the chain and then back down until it hits the frame and is stuck in 2nd gear. End of Race for me. My first mechanical DNF! Now What? It was working fine at the beginning of the race as I took the holeshot in the Ironman class.

The bike is a 2011 250xc Race that I bought new in December of 2011. Less than one year old. Is there any chance this could be covered under warranty?

Any ideas as to what is wrong, and what I will need to fix it?

I should mention that the splines are fine. This is definitely internal.

Thanks for any help given.

 

[twowheels]

You're likely looking at a shift return spring thats broken or come off it's post or possibly a scorpion failure. Iirc you'll have to take the clutch and right cover off to remedy.
It's unlikely to be under warranty (it is a year old race bike) but the great news with GasGas is that you can talk to the bike importer directly and on a first name basis.
Good luck and keep us posted.

 

[singletracker]

O.k., I've started removing the right cover, but it seems to be hung up on something towards the front of the engine. I took the water pump impellar off, but I'm not for sure if there is other parts of the water pump that need to be removed or if it is something else. I don't want to force it and break something.

 

[twowheels]

You don't need to pull the impeller, but it does need to be wiggled a bit. Did you remove the pv cover?

 

[Cruiser]

The shift shaft most likely broke free inside. My 03 did the same thing.. I had mine tig welded by a friend. A couple beers and I was good to go..

 

[andoman]

When I pulled my RS cover to take up the slack in the PV, mine was stuck at the front, too. I don't know what mine was hung up on, but I wiggled and wiggled, and suddenly it was free.

 

[singletracker]

I finally got it off after getting more aggressive with a rubber mallet, but I don't see how its possible to get the shaft out without taking the clutch out. I read somewhere that you don't have to take the clutch out, but I don't see it happening.

I guess I'll go at it again tomorrow after work. I'll welcome any other suggestions.

 

[twowheels]

I finally got it off after getting more aggressive with a rubber mallet, but I don't see how its possible to get the shaft out without taking the clutch out. I read somewhere that you don't have to take the clutch out, but I don't see it happening.

I guess I'll go at it again tomorrow after work. I'll welcome any other suggestions.

The clutch has to come out to extract the shift shaft. Make sure to keep track of the nylon cone (not supplied with new shift shaft) if a broken shaft is in fact what you have.

 

[singletracker]

I got it all apart a few minutes ago, and the weld is broken where the scorpion mechanism is welded to the shaft. I've got to tell you I'm not real happy about having an internal failure for no apparent reason.

BTW, thanks for all of the advice.

 

[twowheels]

I have a scorpion in stock if you need one.

PlusOnePerformance

 

[singletracker]

Do you mean the whole shaft plus the scorpion mechnaism?

 

[rgranger]

Well at least you didn't have ball bearings go rattling around from the water pump, shifter failure is at least a manly failure opposed to a limp water pump - oh the humiliation....

 

[singletracker]

Dude, I wouldn't admit that in public if I were you.

 

[rgranger]

Well I haven't mentioned all the places my balls wound up afterwards... getting old is hell boys!

 

[gasgasman]

Make sure to keep track of the nylon cone (not supplied with new shift shaft) .

Does the cone come out with the shift shaft?
I did one before, but don't remember.

 

[singletracker]

Yes it does.

 

[andoman]

Careful!

Do you mean the whole shaft plus the scorpion mechnaism?

I advise caution: Perilli may sue you....

 

[Cberg]

I lost my shifter when I was on a ride on Saturday. I was thinking about it last night and remembered this thread. I am guessing the shaft broke.

Does the shaft just slide out once the right side cover and clutch basket is removed?

 

[Jakobi]

I lost my shifter when I was on a ride on Saturday. I was thinking about it last night and remembered this thread. I am guessing the shaft broke.

Does the shaft just slide out once the right side cover and clutch basket is removed?

Yep! Shifter off the left, and the whole assembly pulls out the right.

 

[GMP]

This problem pops up occasionally. It used to be common for the scorpion to stick due to a rough surface or weld spatter on the shaft part. Hadn't heard much lately until now. Some things never change I guess.

Everyone should check that assembly visually at the first opportunity. I you take the side cover off for the pump impeller fitting its a good time. If the welds look small and/or crappy, pull it out and Tig it better, then dress the surfaces of the sliding parts smooth. I did this to my '03 and '07, my '07 does shift smoother than my '12.