P200E sticking from 2nd to 3rd gear – at wits end

[peteruk]

P200E registered in 2000, 14k miles


Gear sticking intermittently going from 2nd to 3rd. Pretty much un-rideable. Really need to crash through the gear to make the change. The problem seems to get worse when the engine has been running for a few minutes and significantly worse when fully warmed up.


Been to 3 good scooter garages (and 1 not so good) but no one seems to be able to find the fault. Don’t want to sell on and give someone else the problem.

• Clutch has been checked over – seems OK
  
• Cables replaced and gear handlebar checked.
  
• Selector box is fine.
• Gears checked over and all look OK.
• New cruciform and selector rod. (slight 'scratchiness' when old selector rod came out but now moving freely)

Would really appreciate any advice on what to change next. Maybe the engine case is damaged? New clutch?

Thanks in advance .....

[adrian]

Nice introduction, welcome to the forum 👋

[gpowell]

You appear to have looked at the obvious things, but not knowing the history its difficult to be clear on when it started and how its progressed.
Are the gears meshing correctly, good quality cruciform used, are the gearbox and selector correct corresponding type ie EFL or pre EFL.
I note in title you say P200E, reg 2000. Is it an imported reregistered P200E or a PX200EFL... Reason i ask is they have different layshaft and selectors and cannit be mismatched.
Cant see it being casing but a through check of them for any marks should done, check all components in the casings
Have you checked it selects gears without cables connected, using the selecter by hand while turning back wheel?
It looks like another strip and focus on the clutch and cluster if you think the the gearbox and selector are good.

[peteruk]

Thanks for the reply.

I've had the scooter about 6 years. Stiff gear changes got a lot worse after someone mangled the clutch trying to "fix it"the Even though someone else reconditioned the clutch, it might be good to start with a new clutch to rule it out.

It's a PX200E registered in 09/2000, rather than EFL - useful to know about the specific differences.

Will check other points out.

Much appreciated.

[scooterbooter]

There's a nob of a washer that is easily forgotten. If you need one you need one if you don't you don't .between cruxiform and rod.

[scooterbooter]

Does it change gear if you bite the end of your revs with clutch so it's all spinning nicely?

[peteruk]

It can stick no matter how high the revs are and how I use the clutch when trying to change gear.

Gears seem to change OK when you just rock the scooter through the gears without the engine running.

Interesting to hear about the washer on the cruciform.

Cheers.

[gpowell]

The washer depends on what gearbox/layshaft/selector. The washer is part of early mk1 set up

www.ebay.co.uk/itm/151717055458

As opposed to the later type

www.ebay.co.uk/itm/192507407138

The cluch is not directly connected to tbe gearbox, it transfered through the cluster.
Check the cog condition on the clutch then check the cluster and its meshing with the gearbox.

[peteruk]

  Thanks everyone. Will post again once we find out what the fault is....

[scooterbooter]

Aahhh the one with a washer is for a mk1 !!!!
The kit I bought for a cat version had a washer. Once again I've bought a pile of shizzle of the computer. I fitted it without the washer I'm glad now.

[newyork72]

Sorted. Turned out to be the clutch. Won't bother trying to recondition again. Thanks all for the advice.

[scooterbooter]

Yay! Really glad for you. Yeah the old 'go back to the last thing you f'ed about with'
Glad it ain't just me. Now go them tiger!