Forum

[Ivor]

I`ve had my 2003 Classic running well for weeks, using it everyday and enjoying it. I did have a clutch slipping problem when I got it so replaced some plates, put in a Hitchcocks spring set and changed the pushrod thingy for one with a bearing in it.
It`s been working fine for weeks. No slipping and reasonably easy gear changes. Yesterday it became really hard to get into gear from the off and when moving. Tried adjusting the cable up a bit but that's just made it slip again. Read on another forum that you should not tighten up neutral finder too much, is this right? Anyone know of a solution to what is probably a common problem?

[Gwilly]

Ivor perhaps you could remove the cable and check for frayed strands, could be about to part company. Constant readjustments are a sure sign of cable stretch..90% go half inch from the gearbox nipple, others from the handlebar lever.

A sod to find is the one under the mid cable adjuster. Hence remove and check or just replace if old and doubtful. (cable that is)..

As for the neutral finder the designer did not allow for the nut to be left loose in order to work..

Last thing you want on a enfield.. Think about it.. Usually two things.

Somebody has replaced the end cover and lost the thick spacer washer that goes on the square shaft..

Without it the lever rubs against the outer case and makes shifting difficult, leaves a score mark on the alloy..
Two.. tightened the outer case screws and then fitted the neutral lever.. wrong, the lever will bind in the hole as not central..

Tighten lever first with the case screws slack then tap the case with a rubber hammer/wood to centralise the shaft, when it moves freely then tighten the case screws fully.. gwill

[Ivor]

Hi Gwilly,
Thanks for the reply. I had my doubts about leaving things loose. Will put new cable on it but I`m thinking I maybe need to adjust the selector mechanism. Pete Snidel goes into great depth about this in his manual. I did notice today the neutral finder moves up as I change gear. I had the cover off a while ago to put in the cover stiffener that Hitchcock's sell and it worked fine for weeks. I did as you say, leave cover loose until lever is fitted. Now, all of a sudden, it is very hard to get into gear. It will go in and stay in but I have to force it.

[Norm]

If it has been working fine for weeks it is unlikely a problem in the selection parts because it is only the adjuster plate that can move and that is unlikely, most likely a clutch problem

[Gus Reboullet]

be sure the lock nut on the detent plunger is still locked in place. otherwise the plunger may have worked its way out of adjustment.

[Gwilly]

Ahsoo, Your sure the stiffener is nicely in line with the enlarged hole you drilled in the outer case.. Misalignment could tension the case against the neutral lever..

Does the lever seem to move without binding? Next would be clutch drag, with the engine running and the bike on level ground, get into first gear and with the clutch fully in can you paddle the bike backwards with your feet? If not then its definitely clutch probs..

Unlikely to be change ratchet mechanism as symptoms are usually over or under changing into false neutrals..

Could be the lever return spring or figure of eight ratchet spring, this would make selection a bit vague..

Sorry to muddy the waters but diagnostics by net is a nightmare.. gwilly

[Ivor]

Thanks again for your comments.
Will go through all these points at the weekend and will report what I find.

[John M]

I had a problem with my English Bullet when the clutch needed constant adjustment, turned out it was the nut that holds the clutch basket on the mains-haft coming loose. Should be less likely on your gear box as the nut should be a nylock type, but worth checking if the cable and release arm are ok.

[simon]

The nylock is no guarantee again the clutch coming loose. I found mine was loose so made a lock washer that has sorted the issue.

[Ivor]

That's a good point. When I was in there a while back changing some plates and the springs,I did notice the whole clutch unit was loose. It slides up to a big circlip and wobbles about. I just thought that was acceptable movement but maybe not. Last weekend I took out the indent plunger and checked it, all ok. But since then it has been okay. I have even been able to get neutral when stopped in gear with the engine running! Didn`t even think that was possible. So my gearbox has gone from being a pain to being a dream. Is lots of movement of the clutch basket normal. Or is my clutch about to fall off?