Self Tunning - Khyber G-10 (Plugs, valve clearance, spark gap etc)

[adyiator]

Hello pakwheelers,

my khyber's gear shifting has become very hard. Yesterday, I was roaming in 2nd gear, with no foot on the padal. & after 10mins, when i tried to shift the gear, it was stuck on second, I pressed the clutch but couldn't free the gear lever from second. After some tries, it got free, i thought clutch cable has jammed up, and i thought i won't be able to engage the gear. But i was able to engage it in all gear without no sound.

today I changed the gear oil, but still the gear gets stuck, and i don't know the reason.

Please help.

[smijaz]

ye kia alien talkin ho re hy..
wat baring inside the ditributor?
wat wheight?
wat O/H?
wat shaft?
wat suction?

hum nalaiqooo ka b khyayal rakah kro g:p
lol

LOLz, pardon my rudeness ,

I will need a picture to explain the above queries, so i will get back with pic / details tomorrow (Friday)

[smijaz]

Hello pakwheelers,

my khyber's gear shifting has become very hard. Yesterday, I was roaming in 2nd gear, with no foot on the padal. & after 10mins, when i tried to shift the gear, it was stuck on second, I pressed the clutch but couldn't free the gear lever from second. After some tries, it got free, i thought clutch cable has jammed up, and i thought i won't be able to engage the gear. But i was able to engage it in all gear without no sound.

today I changed the gear oil, but still the gear gets stuck, and i don't know the reason.

Please help.

Your gear's shifter arms may have worn out or 2nd gear kara is damaged and you may notice sticking of the gear lever while its in 2nd, 4th, or reverse (these gears are engaged by pulling the lever down). the oil change will make no difference.
There are three adjustment screws on top of the gear box, may be, i mean may be, minor adjustments can solve the issue.

I havent done this my self so dont know the exact mechanics of this adjustments.

see a gear wala (Gear specialist) or a good mechanic.

[Xulfiqar]

buy a genuine new distributor cap and rotor

and for the transmission guy - you probably have a worn shift fork inside the transmission

[daniyalahmad]

Your gear's shifter arms may have worn out or 2nd gear kara is damaged and you may notice sticking of the gear lever while its in 2nd, 4th, or reverse (these gears are engaged by pulling the lever down). the oil change will make no difference.
There are three adjustment screws on top of the gear box, may be, i mean may be, minor adjustments can solve the issue.

Well I,ve been noticing some similar kind of things in my gear lever.
But the difference is that I feel it quite difficult while shifting to 1st and 3rd gear.
5th gear is rarely used in local so dont know if it having the same problem or not.
2nd,4th and reverse gear are engaged without any problems but whenever I shift to 1st it feels as if the lever doesnot wants to move to 1st position and there is something that is stopping it from going into 1st gear position.
Moreover if I shift to 1st it shifts with difficulty and if I bring it to neutral and then again shift it to 1st then it moves with much ease.
What could be the problem in the current scenario?

[smijaz]

You probably have a worn shift fork inside the transmission

thanks . I didnt knew what to call that shifter thing, "Sift Fork" is very relevant term for it as it looks just like a fork.

One more thing Mr. Xulfiqar, can you plz explain the working of alternator and guide how to diagnose an alternator whether its charging properly at various levels. I have a multimeter and an ohm meter.

[smijaz]

Well I,ve been noticing some similar kind of things in my gear lever.
But the difference is that I feel it quite difficult while shifting to 1st and 3rd gear.
5th gear is rarely used in local so dont know if it having the same problem or not.
2nd,4th and reverse gear are engaged without any problems but whenever I shift to 1st it feels as if the lever doesnot wants to move to 1st position and there is something that is stopping it from going into 1st gear position.
Moreover if I shift to 1st it shifts with difficulty and if I bring it to neutral and then again shift it to 1st then it moves with much ease.
What could be the problem in the current scenario?

I dont think your problem is as serious as the one in the previous post.

Your problem may be just a few plastic bushes in the shaft from the gear lever to the shifting rod on the transmission.

Also Check for
1. vertical play in the lever.
2. Horizontal play (resistance free)
3. when the lever is moved left it comes back in the center with the same force as it come if moved right.

if 1 & 2 are positive you need to get the bushes replaced. you can get the complete set (A grade) for Rs 200 (max)

perform 3 if 1&2 are negative or you have replaced the bushes. if 3 is positive then all is well but if negative then there is play in the shifter assembly and will repaired by opening up the gear box. Consult a good gear wala keeping above info in mind.

[daniyalahmad]

1. vertical play in the lever.

Almost negligible vertical play even in neutral postion.

1. Horizontal play (resistance free)

Alot of play when in neutral, Even when in gear the lever shows signs of horizontal play.

1. when the lever is moved left it comes back in the center with the same force as it come if moved right.

When bringing the lever from left to neutral if comes back slowly,
When bringing the lever back from right to neutral it does comes into neutral with some more force.

P.s I replaced the gear linkage bushes a couple of months back with good quality ones.
Got the set for Rs.280 I guess.

[adyiator]

Your gear's shifter arms may have worn out or 2nd gear kara is damaged and you may notice sticking of the gear lever while its in 2nd, 4th, or reverse (these gears are engaged by pulling the lever down). the oil change will make no difference.
There are three adjustment screws on top of the gear box, may be, i mean may be, minor adjustments can solve the issue.

I havent done this my self so dont know the exact mechanics of this adjustments.

see a gear wala (Gear specialist) or a good mechanic.

Thank you brother for helping me out.

After I changed (filled) the gear oil, for next few hours I couldn't find any difference, But I thought may be the oil hasn't been effectively reached all over, so I thought in morning it will be fine.

& that's exactly what happened, it was only low level of gear oil and the problem is solved now.

But your suggestion is very handy and helpful for future reference.
thanks again.

@daniyalahmad

thanks to Daniyal as well for discussing this issue.

[fas133]

One Very Simple Alternator Test:
1) Start Car and run at a normal idle.
2) Connect a Voltmeter Directly Across the battery Terminals.
3) Turn on Headlights to High Beam.
4) Check the battery Voltage.
*** The Battery voltage should read between about 13.8 to 14.2 volts. (Possibly up to 14.5 Volts.)
5) Increase motor speed to about 1500 RPM. The Alternator should now produce a battery voltage between 14.2 and 14.6 Volts.
*** If it is lower than 14.2 volts, the Alternator probably has one or more Bad Diodes.
6) Now, Maintain the 1500 RPM and Turn off the Headlights. Run this test for One Full Minute.
"The Battery Voltage should NEVER Exceed about 14.8 Volts".
***If it does, the Alternators Voltage Regulator is probably Faulty, OVER CHARGING the Battery.
These Tests are "Meant to be a Guideline". The Voltage Measurements above may not be accurate in all cases.

[smijaz]

@Fas133

thanks for a very helpful info

[Xulfiqar]

get a rod of teflon and a good machinist - open up the entire shift assembly and see where the play is yourself - replace the bushes with teflon ones - and sometimes the bolts that hold it in place on the transmission are worn out too.

[daniyalahmad]

@All thanks for the info.
@Smijaz so whats the plan?
You coming to Islamabad tommorow in your Khyber or not?
If its possible for you then do let us know, we can have a small Khyber g2g.

[cracked]

smijaz bhai u hav my num...let me knw if there comes a gtg...wud love to come meet ya!

[smijaz]

@ Daniyal & Cracked

Dear Brothers, I am at Islamabad right now but didnt came on my khyber because of the "hitchki" issue which has become more intense yesterday especially at higher speeds.

I came on an official assignment by bus and will head back after the meeting on the office transport.

I really appreciate and acknowledge your sincere invite and would have loved to have a meeting at Islamabad as it was well in my schedule for the last 5 days or so.

wish me luck to resolve the issue and plan a PW dedicated trip in near future.

[daniyalahmad]

^ No worries.
Inshallah we will have a meet some other time.
Inshallah your problem will be solved soon.
Enjoy your trip.

[cracked]

no problem ijaz bhai..
maira plan ban ra hy lahore aany ka,will surely bug ya...lol
hope u get ur car fixed soon,it really annoys wen car does some thig stupid n u actually dont knw wats the cause..
u tried alto's coil experiment?

[smijaz]

no problem ijaz bhai..
maira plan ban ra hy lahore aany ka,will surely bug ya...lol
hope u get ur car fixed soon,it really annoys wen car does some thig stupid n u actually dont knw wats the cause..
u tried alto's coil experiment?

Me Back in Lahore

You are most welcome bro...

About the car, There are only two possibilities left one Coil & other distributor.

I have asked about the Alto's Coil as u said kabli one, it is available for Rs. 500, i will get it tomorrow and will hope it solves the problem.

if not then will borrow a distributor from a friend to confirm the diagnoses.

[cracked]

yup..kabli alto's coil i bought was of 450 year or so back...so 500 is good keepin in mind inflation here..LOL
may u get ur car good soon..

acha i have this prob,wen car is in morning or colder environment outside,cars stays stable.but wen its hot outside,car vibrates on idle...ive tried adjusting its air-fuel mixture on cng kit,ive increased rpm but still it happens..wat cud b the prob?
the vibration aint much but r feelable somehow...

[smijaz]

yup..kabli alto's coil i bought was of 450 year or so back...so 500 is good keepin in mind inflation here..LOL
may u get ur car good soon..

acha i have this prob,wen car is in morning or colder environment outside,cars stays stable.but wen its hot outside,car vibrates on idle...ive tried adjusting its air-fuel mixture on cng kit,ive increased rpm but still it happens..wat cud b the prob?
the vibration aint much but r feelable somehow...

check this post my @Xulfiqar, it may be the cause

https://www.pakwheels.com/forums/performance-modification-tune-up-preventive-maintenance/137308-self-tunning-khyber-g-10-plugs-valve-clearance-spark-gap-etc-11#post2374765