Author Topic: EW gearbox stays in second  (Read 716 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.
Andy.

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:

http://www.douglasmotorcycles.net/index.php?topic=4061.msg18624#msg18624

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

-Doug

Offline tck

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Re: EW gearbox stays in second
« Reply #3 on: 27 Jun 2017 at 16:36 »
I am stripping the EW box to try and sort the problem
I have come to the inner cover and removed the single countersunk screw and the upper ratcher mechanism and spring. The large hexagon with the lower ratchet on it looks as if it is a nut that retains the inner cover bearing, is it? and if it needs to undo is it RH or LH thread?

Offline tck

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Re: EW gearbox stays in second
« Reply #4 on: 29 Jun 2017 at 19:00 »
I think my question (above) has been lost in the fog of the forum ....

Offline Doug

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Re: EW gearbox stays in second
« Reply #5 on: 29 Jun 2017 at 23:12 »
Patience, clear weather ahead.

Yes, the inboard ratchet is a nut. The thread is right-hand. Operating the kick start drives it on tighter, and they usually are very tight.

-Doug

Offline oily bloke

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Re: EW gearbox stays in second
« Reply #6 on: 30 Jun 2017 at 17:23 »
I used an air gun to get it off.
Tight as a really tight thing!

Offline tck

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Re: EW gearbox stays in second
« Reply #7 on: 01 Jul 2017 at 08:06 »
Its off! thanks to all.  I did not want to go the wrong waywith a lot of force

Now to find where that gear is sticking....

Offline tck

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Re: EW gearbox stays in second
« Reply #8 on: 08 Jul 2017 at 08:17 »
Yes!
Judicious use of fine grinding paste and a few small bevels did the trick I quite expect it to need more attention in 2019 but its a supprisingly easy job
Thanks to all for your advice