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[Super45]

So managed to have brief time of the bike on friday evening

tried to adjust the clutch and managed to drop the lock nut off the clutch arm so had to whip the covered off to retrieve it but as started to loosen the end cover i thought t sod it lets see if we can get some gears and low and behold i got all 4 gears up and down the box with it not running but a lot of slop in the gear lever as i menetioned on another post you may recall, that was after loosening the neutral finder bolt slightly but not of the cover screws being touched

so is could it be the case that the ratchet mechanism and selector arm inside the end cover is worn to the point that its becoming hit and miss ? as after I rebuilt the end cover id lost the gears again and would only cycle though 1/2 and neutral seems to jam ( not hitting exhaust or footpeg either)

going to wait till pay day then buy nessasary oil and primary case seal to be able to complete the clutch sideof things to rule that out in its entirity

[Jamesy]

I got rid off the crunching into first gear.I think it was the big c clip that holds the clutch basket in was not sitting in place 100%.I have run up 60 miles of gear changing without any problems.

[Super45]

Think my issues are starting to look more selctor based than clutch but will be rulling it out to be sure

[Super45]

Got 5 mins to play with bike last night so carried out an experiment I wound the cable to the max using he bar lever adjuster and the mid length adjuster and also wound in the clutch arm adjuster too , managed to get it to the stage when the kick start wouldnt work so wound cable back slightly it back till I could use it,

clutch at this stage would is niegh on impossible to use as its so heavy and wouldnt be any good on the road, also reached stage where the clutch hit the stop so imaginie this is the clutch at maximum limit as the lever would not come all the way back to the bar where as normally it will

started the bike briedlfy ( still no oil in primary as been waiting for new bolts and a new seal ) and engaging 1st stalled the bike if sat at tick over, adding some revs enabled you to hold the bike in gear on the clutch but you had to hold the bike back from moving forward as it was clutch was dragging and not clearing,

[Mark M]

I found it a bit difficult to understand exactly where you are with this at the moment but one thing I have found is that the neutral finder lever must have a washer (shim) between it and the gear selector mechanism. If you look in the Parts Book it is part number 111196. Although currently listed as unavailable it is easy enough to find something to do the job or it may be in your box of bits. Without it the neutral finder bolt locks the whole mechanism at worst and makes gearchanging almost impossible at best. I found out the hard way with a bike I got as a non-runner with lots of small faults.

REgards, Mark

[Super45]

Sorry mark I know its sporadic but thats due to limited amount of time i get to look at it, to recap., replaced the bars with 50's style ones from our host catalogues and in provess discovere the brake and clutch lever brackets had broken so replaced them, then discovwered the clutch was dragging after only refitting the levers leaving adjustment roughly in same position , at this time the clutch became noisey and discovered the 3 clutch bolts were loose and gouging a grove in the outer chain case and also found clutch basket was loose, and on stripping the clutch that the clutch friction plates in wrong order, tigtend clutch basket nut so no play and rebuilt clutch tightening all 3 spring bolts to the stop. I then discovered that the gears which had previously worked fine and had not been touched would not select 1st 2nd or the proper neutral, only 3rd or 4th, got fed up and left the bike for a fortnight, when i came back to it all 4 gears could be cycled by hand without issue, tried to readjust clutch and lost 3rd and 4th gears straight after, it was then i removed the outer gearbox cover to inspect and clean the clutch arm and regrease, removoing he neutral finder there is only the bolt the spring cover, spring washer gear pointer and the lever itslef, all slots straight on to the selector shaft no sign of 111196 so this could be the issue, although the box has worked fine for around 500 miles ive done with it in past 12 months, i did notice that if i slackered the neutrral finder all 4 gears seemd to selct but this only happend once, currnt stage is what i posted earlier today in terms of clutch

[Mark M]

Thanks for the clarification, sounds like you bought the classic abused bike which has been tarted up for sale! I think we've all been there, I know I have. Try replacing the washer, if you can't get the correct part I don't think the thickness is too crucial but the ones I have used are about 25 or 30 thou. It should in theory be the same one as used in the UK made Albion boxes so our Hosts may be able to provide one, give them a call?

REgards, Mark

[Super45]

Hi Mark

Any idea of the dimentions of the washer especilly its thickness so I can check my parts tin?

[Mark M]

Sorry Super (what's your name?!) I'm not near the garage at the moment. Anyone help on this?

[Super45]

Hi Mark, the names Phil, ( the super 45 hails from a French market classic David Brown 880 implematic tractor that the father in law owns) Abused is the word, the bike herself (nickenamed tinworm for reasons whcih will becoem apparent) could defintly be classed as the classic abused bike, althouth shes had new wheels shocks and ignition switches it seems she sat for 8 years local to me before being bought and got road worthy again by the previouso owner, which consisted of bodges on top of bodges! since ive had her ive had to replace the headgasket ( twice firs stime due to incorect sealant used admiadly my fault ), tighten numerous loose bolts and nuts 3 reg rec boxes, rear mudguard after the rear light fell off due to rust and smashed into pieces new bar lever brackets which broke, and theres a list of other jobs including new centre stand brackets as they have bent allowing he stand to go to far, new tyres as the supposed new onees must of been fitted years ago as have aged considerable since being in day light, new fork shrouds again due to rust, down pipe is rusty and scruffy so wants replacement, replace the rear brake pedal pivot bolt again due to striped threads and helicoiling the rear sump plug as its stripped its thread and held in with ptfe tape!