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[jawa-enfield]

..Together with the engine i overhauled the gearbox.. New layshaft and all new gears on it, new selector fork, all 4 bearings new, new new..
Finally everything together (had some issues with bend layshaft and something else;
Neutral finder works, shifting up works.

The problem. It is IMPOSSIBLE to shift back from 4 to 3, or from 3 to 2.
Adjuster plate all the way down, no result, opposite direction (expected up-shifting problems) also no effect.
When riding, i have to use the neutral finder (that DOES work) and from there to 1st or 2nd.
Sometimes it does shift back from 2nd to 1st.

I spend a lot of money on it and feeling like doing something drastic with a lighter or the neighbours cat.
It soothes me that you cannot see me cry from over there..

Seriously.. I've had BSA, jawa, MZ, ural and dnepr gearboxes.. no problem..
I like the bike! The engine is running very well and the sound with the M20 muffler is awesome..

Am scared i cannot solve this.. Went to a bloke who does classic races and knows these albion gearboxes and he also does not know.

Would be gratefull for solution, or any effort to help.

[Wheaters]

My 4 speed had a similar problem when I rebuilt the gear change mechanism. I followed the diagram in my workshop manual which meant I fitted the ratchet plate upside down because the diagram is wrong.

Reversing it cured the problem.

It should look like an upside down Christmas tree with the top chopped off. Rather than a right way up Christmas tree with its top chopped off.....

[stinkwheel]

I did this once and eventually realised I had the gear lever one notch too high on the splines so it was fouling the neutral finder. When I was trying to downshift, I was lifting the gear lever but at the same time, it was hitting and rotating the neutral finder up.

[vince]

Hi, if the neutral finder can get all gears chances are the problem is in the selector mechanism. 1. Check the plunger mechanism is not to tight and is not rotating. 2. Check both selector springs, the mechanism should centralise with a click . 3. Sometimes the inner gearchange lever butts up against the case restricting travel . Vince

[jawa-enfield]

Thanks all for reply.
Someone asked me if the primary chain is not too thight.. i tensioned it with a little play as in the manual.. should i try slackening it?
Here's a pic of the ratched.. it is right this way isn't it?

Both springs are in working order and the mechanism has plenty (..) play to rotate freely.

Indeed i also had with the diesel, when mouned the gearshift pedal a notch too hight, touching the neutral lever. This is now not the case with this bike.

Can a too thight detent plunger (which by thge way, can rotate in its case, the notch/dent is not so good..)be at fault? Then it should keep into gear more and not less?

[stinkwheel]

Just to check that you are finding this issue with the bike running and on the road and not stationary in the workshop?

[jawa-enfield]

i am working on it know, thinking about a method to re-dent the plunger holder (cannot think of how whithout damage to the thread)
With the detent plunger removed i can see what happens. When shifting back the mechanism doesn't go further, but -just- does EDIT yes it is stopped by the central nodge.
But it does not pull the selector bell(?) far enough.
I did not replace this part, could it be worn out?

[stinkwheel]

This is how far a brand new detent sticks out:


All the parts in the gear selector system are prone to wear.

[vince]

Hi, compress the plunger lengthway in a vice then using a punch indent into the grove. if that fails to work then replace part. If the plunger is allowed to rotate the chisel end will not align with the selector correctly. In the last box I worked on this caused miss selection when changing up. Vince. PS Once this has solved your problem recentralise the selector mechanism.

[Wheaters]

The ratchet plate in the photo looks correctly orientated to me.