Hitchcocks Forum

I have just finished rebuilding my gearbox using new bearings and bushes. I am having trouble selecting gears at the moment. the clutch is disengaging properly but I can't reliably get first or other gears.
I suspect the culprit is the ratchet mechanism in the outer case. The detent plunger may also be wrong as I disturbed it when reassembling the box.
Does anyone know a good way of adjusting these things?

It's an '89 Indian 4 speed.

Try selecting gears by hand using the neutral lever. if ok then trouble probably in selector adjustment. Check if selector ratchet is fitted in wrong direction.

IF the detent plunger has been screwed in too far, you wont be able to change gear...


Back it off a full turn and see if that makes a difference?


The Ratchet inner can be fitted 180 deg 'out'; make sure it is facing the right direction...


When you fitted the inner cover did you ensure that the operating lever engaged with the end of the selector arm?




If the gears/dogs on the mainshaft are not installed correctly, it is possible to have 3rd and 4th gear engaged simultaneously, with catastrophic consequences.

Thanks, the detent plunger is one possibility. The operating lever and selector arm are OK.
The dogs on the gears worry me a little - I think I got them right, no catastrophe yet but I'm reluctant to take the inner cover off again to check!

Each time I see a gearbox / clutch problem (4 Sp) on here my heart sinks. I struggled for two years (on a my daily commute) to try and get a clean gearshift / usable clutch /stay in gear. I tried all the suggestions. I rebuilt the gearbox from scratch with all new parts, except the main case. Replaced the entire clutch from the lever. tried a hundred and one ways to adjust the clutch and the gearbox. In the end I bit the bullet (pun intended!) and installed a five speed. it was expensive, but worth every penny. I now have a bike that will stay in first gear when I pull out into traffic, changes smoothly, and gives my confidence. The improvements to performance, by having better gear ratios makes it like riding something really very different.

A bit expensive for me at the moment! Trouble is, by gearbox really did work pretty well until a layshaft bush went and I stripped and rebuilt the box.

Okay, I'm getting there. I've now realised that the gear selector isn't supposed to separate the two sliding gears on the layshaft;it's supposed to hold them together so that both the main shaft and the layshaft cogs slide together. However, it's more tricky to reassemble the box like that. Can anyone tell me is it possible to re-fit the layshaft without removing the main shaft? I really don't feel like removing the alternator clutch sprocket and chain cases all over again!

It all fits with the clutch in place, you just have to hold your tongue the right way...


Clean and dry ALL parts, NO OIL for initial assembly run(s). It will possibly take you a few 'dry-runs' to get the knack.