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[PeteF]

Well Norm, mine does this (most of the time)
The final bit of the puzzle was getting rid of the gearbox end cover flex. I believe this is where the crucial but important bit of movement is lost.
Mine will engage first with no more than a click and I easily can get neutral at a standstill.
The only time it gets difficult is if it gets hot in stop/start traffic but I guess that's true of most clutches of this type.
Apart from the end cover mod. it's all stock.

[Norm]

Bertie, the missing of one particular gear all the time is the inner ratchet needs to be altered, if it is missing say from third back to second, it is the downshift tooth on third that needs to be altered, it is either not pushing far enough and putting it into neutral between third and second, or it is pushing too far and putting it into neutral between second and first. Getting this sorted is a delicate operation of building up and grinding down the teeth till you get it right. You can get it perfect but as I said you can spend days doing this The 1990 bike Tony is talking about is a clutch drag problem and I don't have a magic ball fix for these, you just keep altering and trying different things and eventually you get them to sort of work, for a short time before they bugger up again.

[Tv]

Thanks for all replies. I have also had a face to face discussion with Norm and he explained how all this stuff works. What I originally did, was basically throw all the gear selector components in a bucket and when reassembling, just picked the first thing off the pile and stuck it into either bike. Big mistake. After listening to Norms logic (and wisdom) I have concentrated on the Super Star as that is my runner. I carefully selected the best parts and reassembled its gearchanger - all working OK now but havent road tested. Even if after a road test its not working properly, I know what to do. Nrom lent me a front cover plate that allows full sight of the inner ratchet as it changes the gears. All looked good but when I replaced the normal cover plate, the problem with going from 3 back to 2 came back so I filed the bottom stop lobe on the front plate a little at a time until I could get all the gears. I'll let you know the outcome after the road test. As far as the project bike goes, that can sit in the corner until I get the good bike even gooder! REgards Tony