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Gearbox.

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Here's a puzzle. With the bike on the work bench, engine not running, I can select from 1st gear to 3rd up and down as I wish with out a problem but go from 3rd to 4th and it gets stuck in 4th. Remove the outer cover and I can lever the quadrant to change down to 1st. If I set the ratchet spring I can then select from 1st to 4th to 1st to 4th several times until it gets stuck in 4th. The gearbox works fine on the road - no problems. I've tried fitting a new ratchet spring from Andover but with the same result. Any ideas appreciated.

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Are you turning the rear wheel at the same time as trying to select a gear? It makes all the difference to going through the gears with the engine stopped. When you think about it, trying to select all 4 without the box revolving, will result in a hang up as the some of the gear dogs will not be aligned. This is not helped by the fact that the commando when on the centerstand usually has both wheels in contact with the ground. You said the bike is on the bench, is the rear wheel resting on the bench so preventing it being turned? 

The centre stand is in good condition (I've even fitted sealed ball bearings to the pivot points!) so the rear wheel is well clear of the bench and able to turn freely. When going up and down the 'box there's only a little movement from the rear wheel required to achieve selection until inevitably it gets stuck in top. Like I mentioned no problem on the road but it is something I'd like to figure out.

Thanks for the reply.

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My guess is pawl engagement with the quadrant. If you search on here you'll find info on adjusting the spring so it's 'just right'.

Why does it work on the road but not the bench? Probably more that the engine is running and rattling eveything around.

I've set the ratchet/pawl spring so it's right according to the Commando Service Notes. The spring must be ok otherwise the gearbox wouldn't change from 1st to 3rd to 1st. The gearbox is not going to be 'rattling around' even on a 360 degree twin - not the ones I build at any rate. 

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The quadrant is in a different, extreme, position in 4th. You could take off the inspection cover and peer inside with a dentist mirror and then tell me I'm wrong...

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My box had a " reluctant " 3rd till i spent some time with a fine stone easing the tight spots on the gear / shaft splines . I had always assumed that after 40k miles these would all be a loose easy fit.,but no.

Thanks, but I should have mentioned the gearbox is high mileage but in very good condition (apart from the fault mentioned). All bearings and bushes are good, it's never had any tight spots. A new AN gear cluster, mainshaft and layshaft fitted at 100,000 miles. Now covered another 70,000 miles. This fault became apparent about 20,000 miles ago and only becomes a problem when servicing the bike. I'm thinking the ratchet/pawl spring is not stiff/hard enough and goes out of tolerance after several gear changes up and down through the box but if that were the case I wouldn't be able to change down at all - according to the Commando Service Notes.

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Reluctant gear changing is often caused by the dodgy springs in the gearbox. Check the two lurking inside the outer cover. The thicker Return spring sometimes cracks. It might look OK from the ouside but the crack allows gear changes in one direction but not the other way.

Likewise and similar to above, the Selector spring has to be a near perfect shape and fitted correctly to function properly. The most common mistake here is to fit it upside down. Check that the straight leg is at the top.  See photo.

The third dodgy spring can be that which operates the Camplate Indent Plunger . Over time, these can go soft and mess up the gear changes. Generally however, this results in just jumping gears.

G-Box

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Thanks for the photo, I'll check the selecter spring. Plunger spring is fine, I replaced the return spring fairly recently.

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This photo is typical of what you can be up against. A small selection of AMC  Gearbox springs all purchased at the same auto-jumble. Ony one from each set actually worked correctly.

more springs

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Agh! Selector pawl springs the AMC 'box Achilles  heal let me down twice many miles away from my comfy bed. 

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Sadly many of their excellent 'how to' guides seem to have gone, but I do have a copy of their notes on setting up the pawl spring in the AMC box. Certainly helped me when I was having 'issues' setting mine up last year.

Hopefully the attachment will open ok.

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