OP
@velasquez avatar
UTC

Addicted
1978 P150X; 1982 P200e
Joined: UTC
Posts: 583
Location: Toronto
 
Addicted
@velasquez avatar
1978 P150X; 1982 P200e
Joined: UTC
Posts: 583
Location: Toronto
UTC quote
Hi All,

I had to replace the clutch side seal in my P200. Once I put the bike all together I am having a hell of a time shifting. Like I have to grab shift bar with both hands to put it into first. With the gear selector box off and back wheel off the ground I can easily spin the wheel and pull on the gear selector rod and go through the all the gears. I’m thinking something off when I re-installed the clutch. Any tips on where to start troubleshooting?

Thanks,

V
@sdjohn avatar
UTC

Johnny Two Tone
'15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4
Joined: UTC
Posts: 8544
Location: San Diego, CA
 
Johnny Two Tone
@sdjohn avatar
'15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4
Joined: UTC
Posts: 8544
Location: San Diego, CA
UTC quote
Clutch cable adjustment, based on the 2 hands comment
@108 avatar
UTC

Ossessionato
V range 50s
Joined: UTC
Posts: 2412
 
Ossessionato
@108 avatar
V range 50s
Joined: UTC
Posts: 2412
UTC quote
+1 on the clutch cable adjustment.

I'd double check the selector box cables too, but i doubt you adjusted it, since changing the seal, but something to relook at if the cases have been split.
@gickspeed avatar
UTC

Ossessionato
Joined: UTC
Posts: 2164
Location: Racing Capital of the World
 
Ossessionato
@gickspeed avatar
Joined: UTC
Posts: 2164
Location: Racing Capital of the World
UTC quote
Poor clutch cable routing; too long of a clutch cable outer.
OP
@velasquez avatar
UTC

Addicted
1978 P150X; 1982 P200e
Joined: UTC
Posts: 583
Location: Toronto
 
Addicted
@velasquez avatar
1978 P150X; 1982 P200e
Joined: UTC
Posts: 583
Location: Toronto
UTC quote
Thanks all, will check the clutch cable routing this weekend
OP
@velasquez avatar
UTC

Addicted
1978 P150X; 1982 P200e
Joined: UTC
Posts: 583
Location: Toronto
 
Addicted
@velasquez avatar
1978 P150X; 1982 P200e
Joined: UTC
Posts: 583
Location: Toronto
UTC quote
Went through all the cables and I think my gear selector cables weren’t tight enough Facepalm emoticon . I thought it was something more drastic. Thanks all!!!

Next question: how do I get rid of the extra length on the gear cable, do I put some solder on it and then cut off the extra length?
UTC

Veni, Vidi, Posti
Joined: UTC
Posts: 7049
Location: Tega Cay, SC
 
Veni, Vidi, Posti
Joined: UTC
Posts: 7049
Location: Tega Cay, SC
UTC quote
Yep. Turn the handlebars, make sure you have enough slack, heat and take of the metal finial, back out the inner cable, cut the outer cable, reinstall the finial, solder and trim the inner cable, set the clutch back up. Done. This works for the clutch and gear cables. Good luck
@sdjohn avatar
UTC

Johnny Two Tone
'15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4
Joined: UTC
Posts: 8544
Location: San Diego, CA
 
Johnny Two Tone
@sdjohn avatar
'15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4
Joined: UTC
Posts: 8544
Location: San Diego, CA
UTC quote
If you just have extra inner, you can do as you suggested, solder and snip
@108 avatar
UTC

Ossessionato
V range 50s
Joined: UTC
Posts: 2412
 
Ossessionato
@108 avatar
V range 50s
Joined: UTC
Posts: 2412
UTC quote
Adjusting the gear box selector cables right?

If I’m not misunderstanding, for cable slack, you shouldn’t need to solder, adjustments done with 2 small wrenches

@sdjohn avatar
UTC

Johnny Two Tone
'15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4
Joined: UTC
Posts: 8544
Location: San Diego, CA
 
Johnny Two Tone
@sdjohn avatar
'15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4
Joined: UTC
Posts: 8544
Location: San Diego, CA
UTC quote
Many times cable inners have inches of extra length, thus the need to shorten
UTC

Molto Verboso
1958 Allstate 177VMC, 1962 Allstate, Yamaha Vino 70cc
Joined: UTC
Posts: 1980
Location: Philadelphia
 
Molto Verboso
1958 Allstate 177VMC, 1962 Allstate, Yamaha Vino 70cc
Joined: UTC
Posts: 1980
Location: Philadelphia
UTC quote
I just cut them down to size and whatever is left over (about an inch or so) gets a cable end like on a bicycle. Dunno if they will work on the shift cables since they are covered in the shift box, I'll find out soon though.
UTC

Ossessionato
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: UTC
Posts: 2537
Location: Siam
 
Ossessionato
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: UTC
Posts: 2537
Location: Siam
UTC quote
Tierney wrote:
Yep. Turn the handlebars, make sure you have enough slack, heat and take of the metal finial, back out the inner cable, cut the outer cable, reinstall the finial, solder and trim the inner cable, set the clutch back up. Done. This works for the clutch and gear cables. Good luck
I had to do just that. My shift outer cables were too long and it was causing it to pretty much not change gears at all. Once the outers are the right length (not too short and not too long; don’t ask me how long that is) shifting will be fine.
@ray8 avatar
UTC

Molto Verboso
Joined: UTC
Posts: 1887
Location: Los Angeles
 
Molto Verboso
@ray8 avatar
Joined: UTC
Posts: 1887
Location: Los Angeles
UTC quote
108 wrote:
Adjusting the gear box selector cables right?

If I’m not misunderstanding, for cable slack, you shouldn’t need to solder, adjustments done with 2 small wrenches
You don't really "need" to solder the ends, even when replacing the cable. Any flare at the ends won't make it to the punch bolt.
Helps to have bike cable/housing cutters. Doesn't start the fraying like pliers or electrical wire cutters. Cost around 13 bucks on Amazon

About housings, a factor can be not seating them properly at the headset, rendering the adjusters at the shifter useless.
Forum member supplied image with no explanatory text
OP
@velasquez avatar
UTC

Addicted
1978 P150X; 1982 P200e
Joined: UTC
Posts: 583
Location: Toronto
 
Addicted
@velasquez avatar
1978 P150X; 1982 P200e
Joined: UTC
Posts: 583
Location: Toronto
UTC quote
I had plenty of length left over on the inner cables. Coated them with a little solder and cut the extra length off with no fraying. First one was kind of messy but second came out better.

Thanks all.
Forum member supplied image with no explanatory text
DoubleGood Design banner

Modern Vespa is the premier site for modern Vespa and Piaggio scooters. Vespa GTS300, GTS250, GTV, GT200, LX150, LXS, ET4, ET2, MP3, Fuoco, Elettrica and more.

Buy Me A Coffee
 

Shop on Amazon with Modern Vespa

Modern Vespa is a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for sites to earn advertising fees by advertising and linking to amazon.com


All Content Copyright 2005-2024 by Modern Vespa.
All Rights Reserved.


[ Time: 0.0133s ][ Queries: 4 (0.0039s) ][ live ][ 313 ][ ThingOne ]