Hitchcocks Forum

Two problems which may or may not be related; I have twice had the outer and inner covers off my gearbox to try to fix them. Firstly, the kickstarter jams. I think I know what is causing this - the pawl is opening and the plunger is coming too far out and jamming against the pawl, keeping it open - but why. Secondly, if I start the engine, put the bike in gear and engage the clutch, the bike moves forward a little then stalls.
As I say, I can't see anything wrong. '89 350 Bullet.

I think something must be worn on the pawl. Either the pawl itself, the ratchet gear or the bush it runs on. Have you tried replacing the pawl and plunger?
With the stalling issue, I think we need a bit more to go on but if there is severe wear in the box this could be pinions locking up. I think perhaps it's time for a gearbox overhaul.

Do you free off the clutch prior to staring the bike and or engaging gear?

What Tim says

I'm thinking that if the Pawl is somehow jamming open, that would jam the gearbox. There is a half-moon shaped plate which is supposed to hold it closed when at rest. Should this be tight or free to move? Does it matter whether the bolt head that secures it is on the outside or inside of the inner cover?
Pawl plunger and spring have been replaced when the trouble started.

That half moon should definitely be tight. I think the screw head has to be outside doesn't it? Sometimes the pawl doesn't park very well and needs a bit of work with a file on the half moon.

John there's a bit of an anomaly with this stop plate fixing.

For 89 the bolt should screw through from the inside, and as Pete says some light fettling with a file may be required to get things just right..

However on later models approx 1999 maybe they screwed through from the outside and the end of the thread was peened/riveted over the stop plate.

Thanks, my bike had the bolt head outside the inner cover, but in the parts book it appears to go through from the inside.
Yes, I did refit the distance washer!