Author Topic: EW gearbox stays in second  (Read 161 times)

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Offline tck

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EW gearbox stays in second
« on: 10 May 2017 at 14:43 »
Just went for a final check run on my wifes 1926 EW just round the village prior to a club run on Sunday all perfect changed up and down came in up my drive and could not get it out of second gear. Two years and about 250 miles ago it it was fitted with a new updated (4?) splined layshaft from the club and filled with grease and its been OK since then, clutch frees perfectly kickstart moves bike in second moving backwards and forwards clutch out  turns engine even gentle force on gearbox arm with adjustable (because lever  rods may bend) does not move it. I suppose its a strip  :( all advice welcome.

Offline oily bloke

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Re: EW gearbox stays in second
« Reply #1 on: 10 May 2017 at 18:09 »
I had the same issue with the club replacement layshaft.
It appeared to me that the new gear and shaft had been machined to modern tolerances and caused 2nd to lock in or out of second.
The entry ramp onto the splines on the shaft had been a little peened due to the crash nature of the box and most likely my getting used to the bike's gear change. I found that adjustment and removing play in the gear stick and actuating arm linkages is necessary.
I gently lapped the shaft and gear with fine grinding paste sliding the gear up and down until it engaged in every direction on each spline/castellation.
After I re installed it I found it had improved but not enough so out again and lapped again making sure the gear rotated to engage the spline without resistance. All is now good. The gearbox has done over 1000 miles since with no issues.
This assumes you have built the box correctly!
Hope that helps.

Offline Doug

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Re: EW gearbox stays in second
« Reply #2 on: 11 May 2017 at 06:55 »
Four or six spline? If the later, see this thread here:

Though that thread deals with shifting through second gear rather than actually being stuck in second gear. But it might give you some ideas.