IWL Berlin noise in 2nd and 3rd

[amkrisis]

Hi

First off, I'd like to apologize for not writing this in German since I don't speak it.
I have a Berlin engine which should be based on an MZ ES150 if I'm correct.

It makes a clunking noise when driving in 2nd and 3rd, and 4th gear is fine.

Apparently I should be able to adjust an arresting pin somewhere to adjust the position of the gears?
Does anyone know where I can locate it? It should be on both sides apparently but this would mean that I'd have to open the left side as well and thus draining the oil and opening the actual engine? Where should these adjustment points be?

Do you guys have any idea what might be wrong? I don't notice any decrease in power or momentum when driving in 2nd and 3rd and it doesn't jerk.
I just hear a very load metal bang which disappears when pulling the clutch.

Might this mean that the gears aren't aligned properly as the IWL forum guys suggest?

Some also say the primary chain might be worn but then I would have the same issue in 4th as well right?

All the help is welcome! All of this is new to me

Thanks in advance!

Benny

[Flacheisenreiter]

Hello Benny,

you're right, there is a shaft which fixes the position of the whole gearchange mechanism.
If you open the dynamo cover on the right side of the engine, you will find the shaft below the sealing cap of the sprocket wheel. It just looks like the other screws of the crankcase.
On the left side of the engine it is locked by a nut and a locking plate.

But, please don't try to adjust the gears without splitting the whole crankcase, because you can't control the right setting without measuring ...
...and those noises and the fact that they disappear while pulling the clutch, show that they are maybe caused by teared down gear parts and/or bearings!

[amkrisis]

Is it visible on the outside of the left side or is it behind the engine cover?

I guess I'll need to open up the whole engine then... oh boy :s

[MaxNice]

benny, the berlin engine is based on the engine of the RT 125. but the gearbox should be equal to the engines of ES and TS. my little TS engine has had a problem like yours it has made clunking noises in 1st 2nd and 3rd gear, maybe you test once more in the 1st gear if there is this noise too. I think I can help you, watch the way of power through the gearbox in the different gears, you will see, the 4th gear is the only one, who doesn't runs over the gear, walks straight through the box. if I opened up my engine I found a toothed wheel wich missed al tooth. look right here: viewtopic.php?p=750655#p750655

[amkrisis]

Thanks! I will have a read using google translate

-- Hinzugefügt: 6. Juni 2011 14:35 --

Mmm, would i need any specialist tools to fiddle in the gearbox? To remove the clutch for example?

[Flacheisenreiter]

Is it visible on the outside of the left side or is it behind the engine cover?

You have to remove the clutch cover, the nut of the shaft is visible on the bottom of the crankcase, between clutch & kickstarter mechanism...

I guess I'll need to open up the whole engine then... oh boy :s

That should be the best way to solve the problem, after overhauling it will run well .

Mmm, would i need any specialist tools to fiddle in the gearbox? To remove the clutch for example?

KLICK Look for "Bücher" "ES" "Reparaturhandbuch für die MZ-Motorräder ES 125 und ES 150", there you will find the instructions to repair the enginge and some drawings of the special tools(wich sometimes can be replaced by something improvised, you just have to be creative ) as well.

[amkrisis]

Just did another testdrive up and down my garage and there definatly is NO noise in 1st gear.

It's there in 2nd but not as loud as it is in 3rd. So the root of this problem might be something else?

A mate of mine who works on Lambretta's and Vespa's mostly thought it might be the linking rod between the footswitch and the gearbox? Seems far fetched but who knows?

I also noticed that even with the clutch fully pulled the scooter pulls forward (slowly) in 1st gear?

[wolf60]

The gear box of the Berlin scooter is well known for problems like those you wrote of. Mostly they are caused by the relief ground of the gear wheels. But if it would be so, there would probably also be another, more serious problem: the gears would "disappear" when driving.

But there might be a more similar cause: Unusual noise out of the gear box (especially when not appearing in every gear) very often is caused by too less gear oil. Have you already checked your gear oil level?

[amkrisis]

I refilled it recently with SAE80w90 so there should be plenty of it.