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Old 26th October 2014, 14:37   #1
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Unhappy Strange sound from Gearbox - Something broken inside?

Dear All,

I own a June 2009 Bajaj XCD 135 which has remained fairly trouble free till date except a starting issue which was solved about two years back.
Last night, while up-shifting from 3rd to 4th and on releasing clutch, a loud and harsh sound came from gearbox and felt as if something has broken inside. I then noticed that there was no feel from gearbox while downshifting, though the downshift was happening.
Randomly, a sound was coming, sound was like pebbles are being shaken in a tin tumbler, whenever any gearshift attempt was made.
After that 2nd and 3rd gears were not engaging, and were slipping back to 1st.
Kick has become a bit loose now.

History of bike related to Gearbox-
1. When the bike was new, shifter spring had broken, resulting that bike was stuck in 1st gear.
2. Clutch plates and pressure plates are new, Engine oil is also 300 kms old and is Motul Full Synth. Bike has run about 53000 kms till date.

I tried starting the bike today morning though, the bike behaved properly with no issues, though shift has become notchy now and shift is extremely jerky now.

What can be the issue Guys??

Regards,
Shashi.
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Old 26th October 2014, 15:05   #2
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Default re: Strange sound from Gearbox - Something broken inside?

The shifter spindle must have got bent. When it gets bent, the shifter drum will not turn completely which causes the gears not to engage properly and make grinding noise.
You will have to remove the clutch cover to inspect it.

As for kick becoming loose- Does the kick move freely when the clutch is pulled ? (I want to know whether the kick is primary in xcd or not)
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Old 26th October 2014, 15:31   #3
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Default re: Strange sound from Gearbox - Something broken inside?

Yes, the kick moves freely when the clutch is pulled.

Regards,
Shashi
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Old 26th October 2014, 17:25   #4
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Default re: Strange sound from Gearbox - Something broken inside?

When was the last time you changed your front and rear sprockets along with the chain?It could be that too.Does your kickstarter move freely downwards with relative ease?
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Old 26th October 2014, 17:58   #5
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Default re: Strange sound from Gearbox - Something broken inside?

Chain sprocket set was changed about 2 years back, but since then bike has run about 7k kms maximum. It is not a chain sprocket sound for sure, it is something related to the GB itself.
When I tried to kick, it felt as if it has become free and only towards the end did I feel some resistance.

Regards
Shashi.
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Old 26th October 2014, 18:02   #6
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Shifter spindle is broken. It will look like a hexagon or a pentagon depending on number of gears.
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Old 26th October 2014, 18:11   #7
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Default re: Strange sound from Gearbox - Something broken inside?

Thanks a ton Sagar for that precise info. XCD 135 has 5 gears- Any guesses about the cost??

Regards,
Shashi
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Old 26th October 2014, 19:31   #8
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Default re: Strange sound from Gearbox - Something broken inside?

Just making guesses and assuming that the shifter spindle has broken is not the whole picture. I recommend that you do not drive the vehicle and make things worse.

Open the clutch and gearbox and you will find something broken. It can be a shifter spring, a dog tooth , a bent shifter rod and fork. It can be a bearing failure also.

Get it thoroughly checked and replace the oil with a new one to avoid contaminants.

Last edited by amit_purohit20 : 26th October 2014 at 19:49. Reason: More points added.
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Old 26th October 2014, 19:40   #9
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Default re: Strange sound from Gearbox - Something broken inside?

Its something in the gearbox, get it opened and checked.
How i know, i have replaced all the gear parts twice in my ex Karizma
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Old 26th October 2014, 20:13   #10
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Default re: Strange sound from Gearbox - Something broken inside?

Quote:
Originally Posted by Leoshashi View Post
Thanks a ton Sagar for that precise info. XCD 135 has 5 gears- Any guesses about the cost??

Regards,
Shashi
For my Pulsar 180 it costed 250 bucks. 5 gears means hexagon(5 +1 neutral)

But like Amit said, it could be some other part also. Stop riding and get it to the trusted mech ASAP
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Old 26th October 2014, 20:14   #11
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Default re: Strange sound from Gearbox - Something broken inside?

Quote:
Originally Posted by sagarpadaki View Post
For my Pulsar 180 it costed 250 bucks. 5 gears means hexagon(5 +1 neutral)

But like Amit said, it could be some other part also. Stop riding and get it to the trusted mech ASAP
Will be taking the bike to the service centre tomorrow morning.

Regards
Shashi
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Old 29th October 2014, 18:54   #12
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Default Re: Strange sound from Gearbox - Something broken inside?

Quote:
Originally Posted by Leoshashi View Post
Will be taking the bike to the service centre tomorrow morning.

Regards
Shashi
Any updates on the cause?Also please try to take some pictures as well when your motorcycle is opened up.Could be a learning experience for some of us.
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Old 29th October 2014, 19:04   #13
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Default Re: Strange sound from Gearbox - Something broken inside?

I just got the bike back from service. The only thing they seem to have done is tightening the clutch cable(very minor perceptible difference). In the list of jobs done, they have also tightened front sprockets. Apart from that, no other work is done. For now, bike is working fine. Shift quality has drastically improved.

Will keep you updated.


Regards,
Shashi
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