Several queries have arisen as to the correct adjusting procedure for this gearbox. Outlined below is the correct checking procedure.
First, remove the kickstart and gearshift levers. Remove the outer chain case cover #611-114-100, then remove the clutch by extracting the circlip #245-020-001 and lifting off the hub complete. Refit the gear change lever, loosen screws #1940-144-000 (no. 17 on illustration page 25 of parts book), rotate eccentrick lobes #31, part #647-103-000 away from motion of travel of pawl, it: anti-clock for L.H. lobe, clockwise for R.H. lobe. Retighten allen screws.
Engage low gear (1st) ensuring that the selector rod part #619-004-001 (part no. 9 on illustration page 22) is fully home. No check to ensure that there is clearance between selector shoe part #248-135-000 and the slot in the selector rod. In other words, make sure that there is no end load on the selector rod. Next, engage high gear (6th) and repeat the above checking procedure.
If any end load exists or if there is very little clearance, adjustment is made by loosening nut, part #642-108-001 and rotating eccentric screw, part #640-110-000 to give the correct adjustment.
Now engage low gear again, ensuring the selector rod is fully home and allow gear change lever to return to neutral position. Then observe the position of the selector pawl, part #248-136-000, when the gear lever is depressed into low gear again, under the return spring pressure. A mental note of the clearance between the pawl and the engaging tooth on selector boss part #286-317-021 must be made as the lever is depressed from the neutral position. Engage high gear (6th) and repeat the above procedure.
The clearance between the pawl and the corresponding tooth on the selector boss must be equal in both gears. If this is not the case, loosen allen screws
no. 17 page 25, and move the selector adjusting plate, no. 16 page 25, part #248-133-001, to ensure that this is the case.
Engage low gear once again, and rotate the eccentrick lobe so that it is just clear of the pawl when the lever is held fully down in the low gear position. Repeat in high gear position.
The gearbox is now adjusted completely and should function satisfactorily.
If the machine is a GS model and has been fitted with the gear locking device, the following additional points should be noted:
Before attempting the above procedure the return spring #639-003-000 must be unhooked, allowing the pawl arm #686-211-000 to drop away from the positive stop locations.
The above proceedure can then be carried out to correctly adjust the gearbox.
To adjust the pawl arm to the correct position, third (3rd) gear must be located. The pawl arm should then locate in the 3rd gear notch on the positive stop quadrant. Select 2nd and 4th gears by lifting the gear changing pawl over the tooth on the selector boss in each case and depressing the gear change lever against the stop. Check to see that the pawl arm moves an equal distance each side of the 3rd gear notch on the positive stop arm. If this does not happen, then readjust the position of the pawl arm by loosening the L.H. allen screw and moving the same. Retighten the allen screw and hood the spring.
Tightening torque to allen screws is 8.7 ... 10.8 ft lbs.
Product Development Engineer