Modern Vespa

Hey group , I have a px200 2007 and I've recently changed all the gear outer and inner cables . And replaced the gear selector box . As my gears were having trouble going into 3/4 . But I've attempted to adjust cables ect but still no luck . I removed the selector box off and twisted the gears and no issues . I put all back together and 1/n/2gears fine but 3/4 are almost impossible to get unless I force . Then going from 3rd to 1st slips past 2nd .. could this be a cruciform issue ? Any help would be great ..

Yes it could be the cruciform, although that would more likely slip out of gear, rather than not going in gear. It could also be the end play is too much, so the cogs are too loose on the shaft. Also could be the selector box, are You sure you had/have the correct box?

Compare your old and new selector boxes to make sure they are the same. There are two different variants of the box and they differ in selector arm throw lenght.

If you need to split your cases to change the cruciform at some point, you should do this kind of check to make sure things line up
1995 Bajaj Chetak 125 - Budget Big-Block Build (Post 2571866)

Thanks for the reply … cogs loose ??not sure what you mean .. I re adjusted and seems better but now having issues when stopping in 1st it's hard to get N .. maybe it's just my cable adjustments are way out !! So frustrating for something simple .. as for the new gear selector box I put the old one on and seems ok so guessing the new selector box is wrong ! But trying to work that out ..

the gear selector arm position is different for each of the gears, especially 3rd & 4th. A difference of 1.5mm, which could be contributing to hard shifting; if the wrong box is installed.

In regard to the loose gears, the faces of the gears wear on each other over time. Shims of various thickness are installed on the ends of the gear stack to take up the extra play, which aids the stack to spin true on the shaft and not wobble. The engine must be split to check, and it should be done while also replacing the cruciform.

First thing I would do is remove the selector.
With the rear wheel off the ground pull and push the selector rod while moving the wheel.
If you can find 4 gears and neutral, the main issue is the selector.

I recently broke a shiter cable on my sprint Veloce. It was stuck in forth gear. Initially I started replacing the inner cable just like I done many times before. The cable wouldn't slide freely because there was a small kink.
I then changed the outer for a new one and everything looked great. I went down to the selector and did my final adjusting of the cable barrels.
At this point I noitice the same excat issue as you are describing. I pulled as much play as I could without being too tight but still 3-4th wouldn't go in. What I found my problem to be was the outer cable slightly off the plastic guide at the shifter mechanism on the handle bar. Basically the outer cable was not 100% recessed into the hole. It was off by 1/4".

Just make sure the outer cable is properly seated/recessed into the shifter guide at the handle bar otherwise it will completely throw off your cable alignments(both cable alignments). Good luck!

Thanks for that .. I did see the cable end at the shifter looked a bit kinked and not flush as it could be . I'll try that and reseat the outer cable in the correct position . Excellent advice thanks

^^ No worries. It can make a world of difference. My outer cable was just sitting above the guide, I was able to shift but I had difficulties. It was hard to spot. Once I recessed the outer cable properly on the guide everything lined up lenght wise. that extra 1/3" can make a world of difference, it can make the shifts just too tight. Always elminitae the cable slack but not too tight either otherwise the shifting can be hard in all gears. Good luck and let us know.

Will do thanks