Scooterotica

put my new cluster in today...and guess what it,s lasted 10 minutes it was ok running through and selecting all gears but has soon has I am in 5th doing 55/60 mph it started slipping to the point it just would not hold doing 35mph..e-mailed rimmini today waiting for a reply..had no problem when I re fitted the 4 speed box after first one broke.who else has fitted the new cluster......getting a bit pissed off now

Is your clutch okay?

I had a similar problem with mine when fitted in February and it was clutch related. Do you have a locating pin in your clutch bell by anychance?

soulsurfer wrote:Is your clutch okay?

reedspeed 6 plate clutch new plates and springs fitted today runs ok with 4 speed box in,the scooter is kicking out 25 bhp I ran it a round steady checked all gears spot on smooth gear change,i gave it some in first 4 gears no problem up to 7000 revs doing 60 drop into 5th and it just jumps and slips same has with the first selector

Stupid question, but obviously you did refit the 5-speed selector when you swapped gearboxes from 4-speed back to 5-speed didn't you?

If it jumps out of 5th then there are a few things to check:


* if the rubber cover on the tie rod is touching the rear shock casting
* if the nearest rubber cable gaitor is becoming over-compressed in 5th gear position
* if the cables are set so that 5th is beyond the 4th marking on the headset - if you do this then you overstress the clutch cable in the headset and it will pull the handlebar gear-change back.
* if the wishbone is touching the casing preventing the cursor from going all the way back into the 5th gear cog properly. (you'll need to physically have the gearbox out again to check this, but it is in the latest assembly instructions)

Speed Demon wrote: * if the cables are set so that 5th is beyond the 4th marking on the headset - if you do this then you overstress the clutch cable in the headset and it will pull the handlebar gear-change back.

Cheap solution: AF supplied clutch outer cables are 2" overlength as standard.

@Yanker I'm not sure that outer cable length is the problem. You will find that even with the gear cables disconnected the gearchanger will only turn so far before the clutch cable starts to get squished between the gearchanger and the cutaway in the headset

Speed Demon wrote:Stupid question, but obviously you did refit the 5-speed selector when you swapped gearboxes from 4-speed back to 5-speed didn't you?

If it jumps out of 5th then there are a few things to check:


* if the rubber cover on the tie rod is touching the rear shock casting
* if the nearest rubber cable gaitor is becoming over-compressed in 5th gear position
* if the cables are set so that 5th is beyond the 4th marking on the headset - if you do this then you overstress the clutch cable in the headset and it will pull the handlebar gear-change back.
* if the wishbone is touching the casing preventing the cursor from going all the way back into the 5th gear cog properly. (you'll need to physically have the gearbox out again to check this, but it is in the latest assembly instructions)

first three are not a problem it will run in all gears and gear selection is not problem,the wishbone hitting the casing this was checked when the gearbox was taken out last time and rechecked when I fitted it with the new cluster,the scooter did run in 5th when I fitted it but when you get on the power up to 7000 revs it slips in 5th to the point it lost drive ............

just back from holiday and have my replacement ., as some have said there is a gap and some cogs look thinner. Thing is what am I meant to do with the original? bin it, send it back or use it as a paperweight?

Speed Demon wrote:
If it jumps out of 5th then there are a few things to check:



* if the cables are set so that 5th is beyond the 4th marking on the headset - if you do this then you overstress the clutch cable in the headset and it will pull the handlebar gear-change back.

Cheers mate,think thats helped me on mine.Every now and agian it jumps but 5th is just past 4th so that should sort that now.
All i got to do is find the time now to fit the new cluster after ive changed nappies and put the boy to bed.