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Makotosun
1977 IT 175
- quidger
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1977 IT 175 was created by quidger
Reassembling motor and I don’t see that neutral on the shift drum has a detent to line up the neutral position or a specific orientation. Don’t want to glue up the cases and find out I missed a neutral tab or line up.
Any advice is appreciated.
Thanks
Sent from my iPhone using Tapatalk
Any advice is appreciated.
Thanks
Sent from my iPhone using Tapatalk
04 Aug 2025 10:03
#1
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- MarkT
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Replied by MarkT on topic 1977 IT 175
There isn't any "timing" or gear the transmission needs to be in during assembly on that model. (BTW, I find it easiest to install the trans into the right case half first)
That said, there is a clear "neutral indicator" I use during assembly as I prefer to assemble in neutral.
On the 77-79 IT175 is the small hole in the left end of the shift drum that will point straight up when trans is in neutral. The DT175 version of the engine has a "rivet" in that hole that contacts the neutral switch when in neutral. On the IT, the neutral switch boss on the case is not drilled and threaded but it's straight above the axis of the drum so it's easy to assemble with the hole in the drum pointing straight up.
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That said, there is a clear "neutral indicator" I use during assembly as I prefer to assemble in neutral.
On the 77-79 IT175 is the small hole in the left end of the shift drum that will point straight up when trans is in neutral. The DT175 version of the engine has a "rivet" in that hole that contacts the neutral switch when in neutral. On the IT, the neutral switch boss on the case is not drilled and threaded but it's straight above the axis of the drum so it's easy to assemble with the hole in the drum pointing straight up.
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1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
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04 Aug 2025 12:04
#2
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- quidger
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Replied by quidger on topic 1977 IT 175
Got it!
Good explanation.
Many thanks for sharing your knowledge.
Good explanation.
Many thanks for sharing your knowledge.
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04 Aug 2025 18:02
#3
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Replied by MarkT on topic 1977 IT 175
P.S. It is possible to install the "star wheel" onto the shift drum 180 degrees out of time. No biggie, easy to fix even if engine is back in the bike.
(The way to avoid is to note the "detent" in the star that the spring loaded lever engages... if you assemble in neutral, easy to see where that wheel engages the "star" at the "half notch")
(The way to avoid is to note the "detent" in the star that the spring loaded lever engages... if you assemble in neutral, easy to see where that wheel engages the "star" at the "half notch")
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
04 Aug 2025 19:36
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Replied by MarkT on topic 1977 IT 175
Or RTFM... there are alignment marks on the drum and star if I remember correctly.
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
04 Aug 2025 19:37
#5
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Replied by quidger on topic 1977 IT 175
I notice an arrow or pointer between 2 of the dowel pins on the flat side of the “star” with the retaining clip.
There is also an area on the circumference of both sides of the “star” between 2 of the pins where the rounded surface is flattened out.
What is the significance of these markings?
There is also an area on the circumference of both sides of the “star” between 2 of the pins where the rounded surface is flattened out.
What is the significance of these markings?
09 Aug 2025 12:42
#6
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Replied by MarkT on topic 1977 IT 175
From the manuals available in tech library here:
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1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
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09 Aug 2025 13:18
#7
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- RT325
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Replied by RT325 on topic 1977 IT 175
You "could" if you wsnted, assemble it in any gear you like. When the cases are together though the star pin piece has to go on as shown in the pic.they probably just say neutral as nothing is engaged at that point, all dogs clear so probably easier. I had a 77 IT175 been through a shed fire so got it for almost nothing. Got it going still looking burnt & found Trans was stuffed which was why it'd been parked up. Me being too tight to spend a dollar I removed the faulty 4th gear. Raced it like that for a while too in the enduro mx class. Just another stupid thing I've done haha. Actually love that bare bones bike, performed great.
09 Aug 2025 14:28
#8
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