1984 honda 125m not shifting correctly

[ps2fixer]

I agree with KB, I have a 125M with the same issue, broken boss .

You will either need to have someone weld it back on, and tell them to beef it up some, or replace the right case half with one that isn't broken. The welder can probably weld it together, just make sure he/she knows what they are doing, no point in paying to get it fixed to have it break again, or have other issues caused from the welding. BTW, You caught it early, mine has the bolt head worn down from rubbing on the drive gear, besides the fact the 3 wheeler came in a box lol.

[Slayer123]

so what parts would i have to order than? just the arm, gasket and a spring? and than i put it all back together and im good to go?

[ps2fixer]

The engine right half case is broken (the boss), so it needs repaired or replace. Gaskets, cleaning, put together, and don't forget OIL! To take off the clutch you will need a special socket. I home made mine out of a pipe, but I wasn't willing to wait for the shipping time for the proper tool at the time. Also the drive gear is held on by a snap ring, so you will need the snap ring tool as well if you don't already have one.


The right half center engine case is part number 11100-968-010, for exact matching only 125M machines will interchange from 84 and 85 based on the part number. It is item #1 in the diagram on this site: http://www.servicehondapsn.com/fiche...84&fveh=132998

Of course it isn't produced new any more, but you could get lucky to find a NOS (new old stock) one, or a good used one on ebay, or just pay someone to fix it for you that can weld/tig.

[kb0nly]

His boss looks ok, the head of the bolt is where its supposed to be, i'm betting just the tip of the arm broke off. Look down behind that gear, do you see the end of the shift stopper arm? Should have a little roller tip on it, but since the spring is off i am betting the tip of the arm is broke off. Make sure you look for it! Usually its in that right side loose somewhere if it broke off.

As for parts...

Shift drum stopper...

http://dratv.com/268n.html

Shift drum stopper spring..

http://dratv.stores.yahoo.net/sdrstsp.html

Clutch nut socket...

http://dratv.com/clutnuttool4.html

Other than that you will need a new gasket for the outer clutch cover unless it comes off in one piece, i doubt it though.

http://dratv.stores.yahoo.net/clutnutcovga.html

It looks like your right cover gasket survived removal, but he has them also if you need one. Be careful with the bolt that holds the shift stopper on, when you reinstall it be ginger with it, they snap off easily and only need like 8 ft lbs of torque, so basically snug!

[Slayer123]

just took the thing apart and it was the clutch drum stopper. it was broke exactly where you said. idk where the extra piece went but it isnt in there anymore... i wonder if it fell out when i pulled off the clutch cover the first time because i did that over the grass. im going to my local motorcycle shop to order the parts tomorrow too! Thanks

[kb0nly]

Just to be sure look it over real good but it probably did drop out. The openings to the center are not large enough for it to get into the middle of the motor. I know cause I took a stopper and checked the roller won't fit through anything on the ones I have worked on.

If you got a local place that can get the parts your lucky! I have no choice but to order

[ps2fixer]

If you need the drum shifter linkage with the 2 stoppers I have one from a 1982 ATC110 that I was going to fix my 125M with. Here is the part number, and what machines interchange based on part number.

http://www.partzilla.com/parts/detai...0-046-010.html

Actually.... I just noticed you can order it new from partzilla for $22.27, your honda dealership can order it too I bet.

[kb0nly]

Dr ATV has them for a lot cheaper!

[ps2fixer]

Who or where is Dr. ATV?

[Slayer123]

just ordered the parts today the stopper was 12 bucks and the gasket for the cover was 14 bucks... haha oh well

[kb0nly]

just ordered the parts today the stopper was 12 bucks and the gasket for the cover was 14 bucks... haha oh well

Not bad at all! About the same price as online...

To answer the other question...

www.dratv.com

Has almost every ATC part you need.

[sammiefish]

(nevermind i think i figured it out, ignore below)


sorry for the digging up this old post... but...

I have this problem too... (84 125m) have all parts on the way... including the big case gasket...
BUT, I cant find the clutch nut gasket in my diagrams... that is referenced just above... the round one
from dratv. I dont see it listed in the gasket kit diagrams?? hmmm... what is this thing...

[honda 200m]

is your clutch tight enough

[sammiefish]

Opened her up today. My shift stopper was fine. It was the case boss for the bolt that was broken. Arrrggghhh. I'm going Tuesday to get 'er welded.


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[sammiefish]

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