Now what? stuck in top gear.....SOLVED

so i had the gearbox inner cover off to replace the kickstart pawl and essentially was a straight forward job. replaced the mainshaft nut as well as the kickstart shaft.....I took the bike out for a couple of short rides around town (no more than 10 miles or so). today i went to start it after another short ride and it was stuck in what appears to be 3rd and/or 4th gear. the clutch disengages the gearbox but the kickstart seems to be engaged whether or not the clutch is pulled in. just as side info all gears where replaced the year before last and there has been very little stress on the bike in that time. I rarely push the bike to its limits and tend to baby it a bit. I got it home by putting it on the center stand, kickstarting it, holding in the clutch and taking off in 4th gear. i was able to briefly get it into 3rd.
any ideas?
Commando74 aka Eric

I use a very simple method taught me many years ago by a great guy called Vic Warman, who helped me sort out my 1971 commando many times.

He always said to me - if something else is wrong after you have done a repair, go back through the sequence as it is something you have done.

I found I had knock an electrical connection off or put something back incorrectly and low and behold he was right!

He helped me a lot back in the seventies and I came to no it as 'Vics' rule.

Perhaps you should try 'Vics' rule.

Eric,
When the gear change lever does not engage in the pawl it usually is the thin hairpin spring inside the outer cover has rusted through or has lost tension. Replacing this spring will usually cure it.

With the engine off, you should be able to find neutral by putting a wrench on the gear selection indicator bolt and while slowly turning the rear wheel, gently turn the wrench slightly to select the next lower gear. If this bolt is not done up very tightly this may not work as the bolt may loosen before the next gear is selected. I have used this technique to select a lower gear when the pawl spring has broken.

When in gear, the kickstarter will be engaged with the rear wheel when kicking, regardless of the clutch position. The engine, however, will be disengaged when the clutch is pulled in.

Another thought. Because you had the box open so recently, check to see that the shift pawl spring is oriented so the "double cranked leg" is downwards. If oriented the other way, it can slip out of position.

check this out.....is it possible the Ratchet Spring, that very thin hairpin spring on the gearshift mechanism, can be mounted upside down? when I took the outer cover off the spring appeared to have not found itself back into the groove on the gearshift stop plate, thus the gearshift pawl could not seat back into the Ratchet Plate.

I have now disassembled the gearshift mechanism and flipped the spring and it looks as if problem is solved.......i think.

what a small mistake......so everyone remember "Vic's Rule".

will report back in the morning with a follow up after a test ride..

thanks Gents..............


over and out,
Commando74

Ron,
I was typing about the exact issue while you were posting your follow up.
anyway that was the answer!
thanks man!
Commando74 aka Eric

Ron L said:

Another thought. Because you had the box open so recently, check to see that the shift pawl spring is oriented so the "double cranked leg" is downwards. If oriented the other way, it can slip out of position.

Click to expand...

that pesky thin ratchet spring was the culprit. removed outer cover, removed the spring, flipped it over and voila.....

shifts fine now.

thanks for the help guys...

Commando74 aka Eric