Trouble Finding 1st Gear After Start-up (Kick start)

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Dan1950 said:
The clutch has brand new Barnett plates installed dry.and it is adjusted correctly. The steel plates were cleaned with brake cleaner and the primary is filled with 7oz of type F transmission fluid.
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After a few minutes running the plates will no longer be "bone dry" as that ATF will have been thrown all around the inside of the primary case and the clutch isn't a sealed unit so it will get into the clutch.


Dan1950 said:
I loosened the primary chain but cannot road test the bike right now as I am working on other components. If that doesn't cure the problem I will remove the outer cover and check the spring on the shifter pawls.
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As it already selected all gears "on the bench" then the problem is unlikely to be the pawl spring adjustment as an incorrectly adjusted spring would result in missed changes due to the pawl not engaging with the ratchet generally in one direction either when selecting up or down in which case you would feel only return spring resistance when operating the gear pedal and no resistance from the ratchet mechanism.

Dan1950 said:
I replaced the sleeve gear, the fourth gear layshaft gear, all bushings, all seals the kickstarter spring and the pawl spring.
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It's possible that things just need to be left to bed in for a while.
 
L.A.B. said:
After a few minutes running the plates will no longer be "bone dry" as that ATF will have been thrown all around the inside of the primary case and the clutch isn't a sealed unit so it will get into the clutch.




As it already selected all gears "on the bench" then the problem is unlikely to be the pawl spring adjustment as an incorrectly adjusted spring would result in missed changes due to the pawl not engaging with the ratchet generally in one direction either when selecting up or down in which case you would feel only return spring resistance when operating the gear pedal and no resistance from the ratchet mechanism.



It's possible that things just need to be left to bed in for a while.
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The gearbox only has about 75 miles on it since the rebuild.
 
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if it is up and down shifting on the road than you have nothing wrong in the gearbox. it can be normal for it not to go into 1st gear from neutral at a stand still as the dogs on second lay have to line up with the engagement holes in 1st lay. with a complementary disengaged clutch nothing is spinning and that is why you have to very slowly engage the clutch while holding up pressure on the shift lever so the dogs can come into alignment.
 
bill said:
with a complementary disengaged clutch nothing is spinning
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With a cold engine, I would have said mainshaft and layshaft 1st gear continue to rotate from clutch plate drag too fast for the 'pin' type 2nd gear dogs to engage with layshaft 1st.
 
To set the hairpin spring:
first, make sure the pawl spins freely without binding.
Hold the assembled outer cover vertically in your hand or in a vise, in the same position like it is on the bike.
The pawl will rest on the lower spring leg.
Move the ratchet plate through its arc, and see that it does NOT touch the pawl.
If needed, gently bend the tip of the lower spring leg.
Then adjust the higher spring leg so that it JUST clears the pawl ( minimum clearance).

Also: See that you have the later type stop plate ( bigger hole):


Trouble Finding 1st Gear After Start-up (Kick start)
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If you have the older type( unlikely) , check that the pivot pin doesn't touch the stop plate.
 
Dan1950 said:
I backed off the tension on the primary chain and finding 1st gear after start-up is now much easier.

Over all the shifting has improved too.
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Yes this was my experience when mine starting getting difficult to engage 1st from neutral. Seems to be fully cured now.
 
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