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[gringo]

can anyone tell me how to set up the selector/ratchet on a GT connie, I can get gears going UP the box ie 3-2 5-4 but all I get going down is neutrals and then with an upward nudge find a cog, is the cover plate on the ratchet to blame or is the rod length the culprit ??? the bike passed its MOT yesterday after a long spell off the road and an engine rebuild including a new spring on the ratchet mechanisim.

[Mark M]

On the left side of this page is a tab marked Technical Notes. Go in there and click on 250 engine rebuild. A full explanation of how to set up is near the end of the article. The box on mine works ok but needs care, I don't think they'll ever be fantastic! Good luck and let us know how it goes! REgards, Mark

[big al]

Hi gringo. may I wish you the best of luck. When I rebuilt my GT. it was the gear box that gave me the most trouble. I followed the manual and tech notes over and over again, but I did finaly master it. adjust- road test....adjust- road test and after 18 months I had a gear box with no neutrals and all the gears. It was a great feeling to have got the box right and after all the frustrating work found it was well worth the effort. The only thing I can say is stick with it all the best. Alan

[Howzie]

Hello Gringo,

When I rebuilt my 1959 250cc Clipper the gearbox was the beast of all, like big Al says, it took me months to get it right.
Can I just mention that you must have no play what so ever in the gear changing operation, when you move the gear lever up or down you should see the gear ratchet move straight away! if not you will have wear in some if not all of the moving parts with the gear change assembly and this must be rectified before you go any futher.

When your happy that this is ok get the bike on the centre stand with a bit of plywood under the stand on the generator side so you can turn the back wheel when trying your gear changing. Make sure the pawls on the ratchet are equal when your in say 3rd gear then mark the adjusting rod so you have a reference point to go back to, the start by turning the adjuster up or down a fraction at a time till you find all the gears.

Cheers.

[gringo]

Howzie when you say check the pawls are equal in 3rd gear to see them the cover plate ( the one with the 4/5 gear cluster marked on it and stops the travel ) must be removed first to see what is happening is this correct and does it make any difference??

[Howzie]

Hello Gringo,

What model is your machine, the info I sent was for my 1959 unit constuction 250cc 4 speed clipper.

When I remove the gear lever, kickstart, footrest & exhaust then take the generator cover off I have full access to the gearchange assembly, also at the gear lever there is that large spring that returns the gear lever to the central position it has two screw stops one for up and one for down, I removed them from my bike as I felt the gear lever still was wanting to travel up/down a fraction and it worked.

Cheers.