Gearbox issue....

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JOHNO23

JOHNO23

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Jul 27, 2009
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Good afternoon...........again!
I’m coming to the end of my mk 3 rebuild.........I fitted the clutch alternator and starter all was well in the world. That is until I put the gearchange on and tried to select neutral. When I put the outer cover on, the gearbox was in top gear (quadrant at highest point)which is correct I believe. Well it’s correct for when you fit the inner cover,so I left it in that position as no instructions I have read advised me otherwise. A new ratchet spring was fitted with dogleg in correct place and had clearance both sides of the pawl.
Tomorrow, I will remove the outer cover and have a look. Any thoughts as to what I may have done wrong ?
it was all going so well...... :mad:
 
Is it only neutral? Does it change as it should on all gears? With rear wheel rotated a bit?
 
When you set the clearance on the ratchet spring the clearance should be the minimum possible.

From Old Britts

The ratchet spring (04-0038) is bent correctly so the legs DO NOT touch the gearshift paw (04-0024), but there should be just a very small but perceptible clearance on each side.

Gearbox issue....


Before you put the other cover on did you check that by levering the quadrant with a large rod in the hole you could change gear whilst turning the gearbox sprocket or rear wheel.
 
I’m sure I set the ratchet spring pretty much spot on to how you show it there....
I didn’t lever the quadrant though...........
 
You have to take the outer cover off so try the quadrant, if that passes then you know the issue is between the inner and outer cover.
 
How tightly have you set the neutral switch?
If this is screwed-in too far, the spring plunger puts a lot of pressure on the camplate.
 
Spent most of the day trying to work this out!! :mad:
moving the quadrant, I have all gears whilst turning the rear wheel.
When I fit the outer cover, I may be able to select the odd gear and find a neutral, but I
certainly can’t go up and down the box! i can see via the gearbox filler that the ratchet spring is moving but at a guess the pawl isn’t locking in place to move the quadrant......HELP! :(
here are pics of my outer cover...........any clues?
Gearbox issue....
Gearbox issue....
 
With just the outer cover move the gearchange shaft as it needs to to change gear. Observe the ratchet, if it does not slant over then adjust the spring gap until it does, based on your pic less gap is needed.
 
That "Old Brit's" picture being shown is their example of how NOT to do it. http://www.oldbritts.com/gearbox_a.html I set the clearance so that I can feel the clearance, if not actually see it. That said ...I recently rebuilt the original box on my '72 Hi Rider and the pawl spring was so tight, it had worn serious grooves in the pawl. It always shifted fine.
 
JOHNO23 said:
When I put the outer cover on, the gearbox was in top gear (quadrant at highest point)which is correct I believe.
Click to expand...

The quadrant sometimes looks as if it's right but can be a tooth out.
 
That spring does look way OTT to me.... As mentioned elsewhere the gap should be 'barely perceptible', but absolutely NOT touching..
A pain to achieve sometimes, and fun refitting on the Mk3, but such is life with old bikes :)
 
EstuaryBoy said:
That spring does look way OTT to me.... As mentioned elsewhere the gap should be 'barely perceptible', but absolutely NOT touching..
A pain to achieve sometimes, and fun refitting on the Mk3, but such is life with old bikes :)
Click to expand...
I have tried it with less gap than in the pic, but will go again today........:rolleyes: The words “Heath Robinson” springs to mind................:D
 
JOHNO23 said:
Spent most of the day trying to work this out!! :mad:
moving the quadrant, I have all gears whilst turning the rear wheel.
When I fit the outer cover, I may be able to select the odd gear and find a neutral, but I
certainly can’t go up and down the box! i can see via the gearbox filler that the ratchet spring is moving but at a guess the pawl isn’t locking in place to move the quadrant......HELP! :(
here are pics of my outer cover...........any clues?View attachment 17606View attachment 17607
Click to expand...
With the cover off.
And with the gearchange plate inserted along with the external gear change lever
Holding the cover so it don't move along with the gearchange plate to give a resistance, you should be able to select all the gear up and down and observe how the pawl behaves.
 
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