Strange sound from Gearbox - Something broken inside?

Leoshashi · 26th October 2014, 14:37

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.

interc00led · 26th October 2014, 15:05

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)

Leoshashi · 26th October 2014, 15:31

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

Regards,
Shashi

B O V · 26th October 2014, 17:25

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?

Leoshashi · 26th October 2014, 17:58

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.

sagarpadaki · 26th October 2014, 18:02

Shifter spindle is broken. It will look like a hexagon or a pentagon depending on number of gears.

Leoshashi · 26th October 2014, 18:11

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

Regards,
Shashi

amit_purohit20 · 26th October 2014, 19:31

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.

akshay4587 · 26th October 2014, 19:40

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

sagarpadaki · 26th October 2014, 20:13

Quote:

Originally Posted by Leoshashi

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

Leoshashi · 26th October 2014, 20:14

Quote:

Originally Posted by sagarpadaki

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

B O V · 29th October 2014, 18:54

Quote:

Originally Posted by Leoshashi

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.

Leoshashi · 29th October 2014, 19:04

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

26th October 2014, 14:37	#1
Leoshashi Distinguished - BHPian Join Date: Jul 2014 Location: India Posts: 5,693 Thanked: 42,422 Times View My Garage	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.
	(6) Thanks

26th October 2014, 15:05	#2
interc00led BHPian Join Date: Apr 2013 Location: Hyderabad Posts: 237 Thanked: 254 Times	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)
	(2) Thanks

26th October 2014, 15:31	#3
Leoshashi Distinguished - BHPian Join Date: Jul 2014 Location: India Posts: 5,693 Thanked: 42,422 Times View My Garage	re: Strange sound from Gearbox - Something broken inside? Yes, the kick moves freely when the clutch is pulled. Regards, Shashi
	(6) Thanks

26th October 2014, 17:25	#4
B O V BHPian Join Date: Feb 2013 Location: Cochin Posts: 307 Thanked: 244 Times	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?
	(2) Thanks

26th October 2014, 17:58	#5
Leoshashi Distinguished - BHPian Join Date: Jul 2014 Location: India Posts: 5,693 Thanked: 42,422 Times View My Garage	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.
	(6) Thanks

26th October 2014, 18:02	#6
sagarpadaki Distinguished - BHPian Join Date: May 2010 Location: Bengaluru Posts: 4,212 Thanked: 5,879 Times	Shifter spindle is broken. It will look like a hexagon or a pentagon depending on number of gears.
	(3) Thanks

26th October 2014, 18:11	#7
Leoshashi Distinguished - BHPian Join Date: Jul 2014 Location: India Posts: 5,693 Thanked: 42,422 Times View My Garage	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
	(6) Thanks

26th October 2014, 19:31	#8
amit_purohit20 BHPian Join Date: May 2006 Location: mumbai Posts: 676 Thanked: 902 Times	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.
	(2) Thanks

26th October 2014, 19:40	#9
akshay4587 Senior - BHPian Join Date: Mar 2005 Location: Chandigarh/Mohali/Ambala Cantt Posts: 4,151 Thanked: 4,525 Times View My Garage	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
	(1) Thanks

29th October 2014, 19:04	#13
Leoshashi Distinguished - BHPian Join Date: Jul 2014 Location: India Posts: 5,693 Thanked: 42,422 Times View My Garage	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
	(6) Thanks