The problem is as follow:
Trying to shift from 1st gear to 2nd gear at low rpm's (below 5-6k) works perfectly. Nice clunk, nice pull forward.
But trying to shift from 1st gear to 2nd gear above 6-7k results in a horrible noise, like a grinding noise, and a bit of pulsation from the shift lever. And gets just to neutral. It's like get trough neutral, almost into the 2nd gear but it can't engage.
If I shift in this way: 1st -> NEUTRAL -> 2nd it works fine. In other words I need to shift to neutral first, I can't jump over it from 1st to 2nd.
The problem was pretty much every time I owned the bike but now it's really bad. Before i could've shift from 1st to 2nd without the clutch and it worked perfectly, now if I try to clutchless shift the bikes goes only into neutral and if I force the shift lever a bit harder does that grinding noise. Clutchless shifting from 2nd-3rd, 3rd-4th, etc works perfectly . (the bike also shifts perfectly in any other gear except 1st to 2nd)
Thinked of possible cooperates for this:
-Clutch cable was loose, I thought it won't disengage properly. (I've changed it and adjusted it. No improvement, maybe just a tiny bit. But no real improvement.)
-RPM too high. It idles around 2-3k rpm. I suspect the carbs, they are not sync'ed. (Gonna do it this weak with some help from a friend)
-Chain, Rear wheel sprocket damper too loose? (Read in some topic here that these little toys are really moody about the chain tension)
-The shifting linkage is really worn out, those black pivots(idk how call them) are really loose, and the mounting of the foot thingy where you press are really worn out and loose. A lot of play from left-right and a bit from up-down. I thought this is the problem because I played a lot with the adjustments and sometimes works a bit better. I looked on the web how it should look stock, now it's in the stock position. The problem still persist.
-Clutch assembly? Springs, plates
-Oil? its 10W-40 Motul 5100 Semi-Synthetic (done just 1-2000km on it, but it was stored over winter with that oil, almost 1 year old)
-And at last... the dreaded gearbox it self (shift forks, gear dogs, gear drum, the shift lever witch pulls on the gear drum, etc)
I'm not a mechanic but I'm no fool either, I've rebuilt this bike from the ground up. The only thing that intimidates me it's the actual gearbox.
![excited :excited](./images/smilies/happy.gif)
Help is much appreciated!