Scooterotica

Have you got a tye rap high enough on the fork tube to hold the cables in position so that the gear outers can't come out of their correct position on the headset clamp? You need to make sure they are right up against their stops in the headset clamp and stay there. Set your gear cables up as per Sticky's book. When you rebuilt the gearbox, did you check the stirrup was right up against the shim before you tightened it up with the correct bolt? Did you check the small pawls on the ends of the stirrup arms were in good condition and not worn? Did you check the two ball bearings and spring that goes through the layshaft were in good condition? (the ball bearings wear and become facetted). Is the gear change shaft bush in good condition? Cables routed under the engine mount? Sorry for all the questions, but these are things I would double check.

Had lots of similar issues over years.

3 things that have bitten me in the past .....

1. Thought I'd be clever and put some of the old style concetenar type rubbers over the exposed gear cables at bottom end. Only after 3 gear box strips to find out the rubber was too hard and did not contract enough to get into 4th gear !!

2. Indian gear swivel on top of crankcase, needed some griniding away on inside corners as they were too square to get 1st gear.

3. Finally , had an engine with one of moveable gear selectors (a la MBD).
Stuart Owen gave me the correct advice on this one, gear selector on outside should have just enough room between your little finger and the rear engine mount, when selector dog is as far into casing as will go (hope this one makes sense !!!!)

Good luck

martin

make sure your selector arm is fullt tightened on the shaft .. mine wasn't and had the problems you describe, the bolt had undone itself!

Got the scoot out first time yesterday and today, about 40 miles on it. checked the cables wernt jumping with the head set off and all was okay after 3rd disc change... Still the same issues with the gears that it had before the rebuild. These being, only be able to get 4th on the last part of the movement when you release the lever, 2nd down to first...dont really happen. It also slips out of 4th back into 3rd with the slightest downward roll on the handle. This is the biggest f****** of all and really pisses me off...

anyway i think all this probably probably leans towards a internal clutch problem as all the outside gear is new (mb) also, when it was built the same bits went back in... didnt think about it in my rush to get her back on the road...

theres a moral here somewhere, but i really dont want to hear it....

sef