Apologies if I'm treading old ground here, but frustration is a powerful mover!
Just 'reconditioned' my Mk3 gearbox, using RGM overhaul kit. So... new bushes, bearings, springs etc. Retimed the camplate and quadrant as per Clymer manual photo... no go.... arm bottomed out on inner cover in 1st gear position.
So... backed up one tooth, now close to position on Oldbritts website, and all clear with inner cover on. Finish off the job, fill with oil (outer cover refitted in 2nd gear position) and with back wheel off the ground ALL gears select easily on the way UP... but once in 4th it's like the lever is disconnected, only using extreme violence can I get it back down the gears!
Made for an interesting ride... great top gear performance but a nightmare for the clutch coming home! It's SO frustrating, as it seems the gears are there... it's just getting the damn things!
Both outer cover springs were renewed and clearances observed, so any suggestions out there?
Enjoy the holiday!
The hair spring in the out…
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Thanks for your input John…
Thanks for your input John, am hoping it is just this spring, maybe I'm not reassembling with enough care! Possibly 'nipping' it in the process.
Mind you, I can't understand how the official Mk3 workshop manual illustrates (Fig. D8, Gearbox chapter) the ratchet plate in position on the inner cover, seemingly held by the pawl carrier pivot?
I would assume the best method is to have the ratchet plate over the pawl spring in the outer cover to ensure all is free to move as nature intended, but what a joy trying to engage with the knuckle roller without disturbing anything!
Oh the joys..............
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I'd also check the spring…
I'd also check the spring, if this is off the gearchange is miserable,yes fitting is a pita and easily dislodged - blob of grease?
Cheers
Mike
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The Old Britts gearbox bui…
The Old Britts gearbox build page has some good pics of the spring in position correctly and wrongly. Bend it until it is just about to touch the ratchet top and bottom in the central position.
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Strange but true! Hoping I…
Strange but true! Hoping I may have found my answer, which is the full pedal travel wasn't reaching the gearbox. The gearwheel on the crossover shaft (in the primary chaincase) had perceptible play on it's splines... cured by turning it back to front.
Also, and this is the kicker.... I fitted an RGM belt, but alas the first shredded itself due to worn sleeve gear bushes allowing it to 'wander'. Renewed the bushes and it ran fine, though the chaincase needed a good cleaning where the belt had turned to powder and iron filings (ouch!)
On inspecting the pedal shaft etc. it became obvious that the pedal gearwheel and the crosshaft wheel were both ingrained with muck, a quick pass with a nail brush got metal showing again. I am assuming that this crud prevented the gears meshing as designed, and by keeping them slightly apart they weren't at peak efficiency. Pleased to say the gearchange action has returned to (almost)normal, but I think it may be prudent to renew a few support bushes as well....
Thanks again for the comments/suggestions.... enjoy your toys!
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The hair spring in the outer cover is easily put on the wrong way and/or not tensioned/shaped correctly which gives these types of symptoms. Might be a good idea to try the old one and play aound.check the new one, You can take the outer cover off and move the gearlever and see the spring and the ratchet spring move. I suspect the spring is only working one way.