Shifter problems

Guys,
I am having issues with my transmission. OK first some history. After 40+ years and around 200K miles I managed to crack the gears box shell. I had adjusted the primary while on the road and I think the tabs on the upper gear box adjuster didn't index into the slot on the cradle. My bad! Because of that the nut vibrated off and the gear box worked back and forth and the shell cracked. I have installed a good used shell and timed the transmission. With the outer cover off I can get all the gears so the timing is correct. When I put the outer cover on it will shift up to 4th and then back to 3rd but nothing else. I replaced the hairpin spring but that didn't change a thing. The new shell had a cam plunger in it so I am using that one. Maybe that's the issue? I will keep looking but I hope your collective insight might lead me to the answer.
thanks in advance.
John in Texas

Update.
Took the inner cover off and don't see any obvious cause for my shifting issue. Rolled the shaft that the forks run on, on a piece of glass to make sure it was straight and it is. I do remember that getting the shift forks to line up when putting it together was a bit of a pain. I have extras so I will replace them and see where that leads. Maybe the "buttons" on the forks where they run in the cam are damaged or the cam plate is warped. The adventure continues.

Is it possible to have 2nd gear main reversed? The pawls should point to the drive side. I feel this would allow 3rd to 4th and back and nothing more, yet is still possible to be assemble this way.

Take a close look at the operational photos near the bottom of this artical.
http://www.oldbritts.com/gearbox_info.html

If you remove the outer g'box cover check that the pawl spring is fitted correct,with the straight leg of spring uppermost.Next is the gear change stop plate.This can be adjusted ,but first mark the existing position on the cast-in mounting lugs on the outer g'box cover.By releasing the bolts the gear change stop plate can be moved up or down.If not elongate the two plate holes 1/32 " to enable the plate to go upwards towards the top of the case.The plate must be retained in this position whilst retightening the two bolts.Should the fault occur when changing into a higher gear, elongate the holes in the opposite direction to the same amount,so the plate can be moved downwards.
If the fault is in changing down move the plate upwards,if the fault is when changing up move the plate upwards.

Paul

Oops
The last sentence should read:- If the fault is in changing down move the plate upwards,if the fault is when changing up move the plate DOWN.
Paul

HRD, what brings you out of the wood? First post in 4 years along with a recall. I hope we from you again.

I thought of the upside down shifter spring. but do not recall an adjustment with the plate it relates to.

The reversed spring has happened to me before, as with anybody doing gearbox work, having a 50/50 chance of getting it right if you don't know the difference. This is generally the first thing to check.

I couldn't recall the symptom other than being able to shift one way but not the other, if I recall.

I quess the reversed 2nd gear main is a radical mistake, put I think it;s possible.

I have been sitting on the sideline reading posts every now and than.I remember a similar fault with a g'box I had rebuilt using a different shell and a mix of parts.Could not select gears correctly.Found the information in a little Matchless manual and it fixed my shifting problems.

Which little Matchless manual would that be? I have some Matchless books maybe I have it and haven't noticed the information before.
John in Texas

Headed for the garage while its still cooler outside.

Ok, we have had our ah ha moment. I decided to install 2nd gear main along with the fork just to look again. With the gear on the main shaft the fork wouldn't align with the hole for the rod without moving the quadrant down a little. That was my ah ha moment. Took it back apart and re timed the shifter. There is more space between the top of the window and the quadrant and less at the bottom. I am going to put the outer cover back on and make sure it works correctly then take the covers off and put new gaskets in.
It's amazing what a good night's sleep and a cup of coffee will do.
I will let you know how it goes but I'm pretty sure I have solved my problem.
John in Texas

Hello John
Hope you have fixed the shifting problem.
Not at home for a couple of days.When at home I will send the title of the book and the page #.
Paul

Been beating my head against a wall trying to figure out what's going on. It's not like I have never worked on a Norton transmission before but for the life of me I can't figure out why it won't time. Thought I had it sorted out yesterday but no.
Recap on what I have done so far.
Replaced the shell and installed the bearings. The lay shaft bearing is the roller type.
Installed the cam and quadrant with new o rings.
New sleeve gear seal, installed the sleeve gear and sprocket. Always easier to do with the main shaft out.
Main shaft installed, main shaft 3rd gear with shifter fork. With this in place I put the fork spindle in and it shifts just fine. Took the spindle out and installed the lay shaft with lay shaft 3rd and 4th gear installed. Installed the lay shaft 2nd gear with the fork and installed the spindle. Wouldn't shift.
So I need to figure out why? Did the lay shaft not seat into the bearing?
I total frustration I have removed the transmission from the bike and I am now working on it on the bench.

John in Teas

Got it! After 2 days of messing with the transmission I got it sorted out. The only thing different I did was to remove the sprocket and use a screw driver inserted from the drive side to keep the shift forks in place while I inserted the spindle.
John in Texas

Hello John in Texas, I am back home now and dug out The little Matchless book ,"Service and overhaul manual for the AJS & Matchless twin motorcycles" by F.Neill
S.B.N. 850770130 .
The gearbox section is on page 30-35.
So is your bike now changing gears correctly?
Paul