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[Himself]

Finally got to the bottom of this if you'll pardon the pun; Cleggy was right, the dogs on 1st (i.e. bottom) gear are badly worn. The loose clutch was a red herring; I began to think it was a bit fishy (sorry). Should I also replacethe mainshaft sliding gear, the dogs of which don't look too bad?

[Cleggy]

If the dogs look flat sided, should be OK. You are the judge. Sliding gear was probably harder then the bottom gear.

[JTL]

Hi Mark M... Thank you for the explanation on the detent plunger... and thank you Himself for pointing me to the tech notes on the gearbox rebuild article. My gearbox has done 34K km and I have been contemplating on rebuilding it with sealed bearings. This way I would learn to know my gearbox and cure some gear change problems too. I'm not there yet, but have already learned a lot from this thread... Jacob