QuestionMy XL185 has a hard time entering first gear while running. It will upshift and down shift through all other gears with no issues but will only hit Neutral while trying to enter first. Or, it will barely grab then slip into Neutral.
Please let me know any temporary fixes and what may be wrong in the clutch. I am not familiar with working on a clutch, I just know its components.
Thank you for your expertise!
AnswerJeff, It may not be a clutch issue.... or it may well be. You didn't say if this was a sudden problem or if the bike has just been revived after long-term storage.
http://www.cmsnl.com/honda-xl185s-1979-usa_model1140/partslist/E++08.html shows the clutch assembly. If you need to take it apart, you will need a special 4 pin clutch nut removal tool, which is available at most shops under aftermarket brands, like Motion Pro.
When bikes sit for years, the clutch fiber plates will have all the oil squeezed out of the material and it sets up a bonding effect that causes the clutch plates to stick together. This results in a no-release condition, where the clutch fails to separate cleanly. The clutch drag or lack of separation altogether keeps all the transmission gears under load and turning, which prevents them from easily shifting from neutral into a gear and from a gear back into another gear or neutral.
If the clutch is NOT sticking, is adjusted properly for just a little slack at the release arm/handlebar lever, then the shifting issues may be either in the shift selector/drum or with shift forks/transmission gears. You can check the shift selector parts when you remove the clutch, but beyond that it is a full motor teardown to inspect the transmission gears/shift fork/shift drum.
http://www.cmsnl.com/honda-xl185s-1979-usa_model1140/partslist/E++14.html
This engine design is based on the 100-125cc engines starting in the early 1970s, which had some issues with the kickstarter gears failing. The replacement gear sets need to be replaced as sets, because Honda changed the gear ratios, so the new gears have a different number of teeth then the originals. Note the changes in part numbers where original numbers have been superseded with newer ones.
http://www.cmsnl.com/honda-xl185s-1979-usa_model1140/partslist/E++12.html
Drain the oil and check the filter screen for signs of either clutch plate disintegration and/or gear teeth/debris from damaged internal parts. If you see that, then your repair efforts may become large and costly. Unless the issue is just sticking plates, there is no "quick fix" or easy solution for the current symptoms.
Bill Silver
