cant get 2nd to 4th gears, stiff movement

[swissdean]

Hi, I've looked at the forum and cannot see this issue so hoping someone can help.

I have a casa 185 and put a new indian Gp200 box in my late Spanish LI125 casing (86 Lynx 125) to make better use of the power. I followed stickys manual diligently and am certain I have the gears facing the right way around (checked and rechecked before fitting), shimmed up and its at the low end..ie 0003 and starts fine, clutch pulls in fine. changed cables so gear selection is spot on..knocks into 1st fine but then as i pull off, it sounds like it its neutral before grabbing 2nd gear, 2nd is lumpy, almost like its intermittently connected and then with a firm twist it will move into 3rd and 4th and run on these gears fine..all very stiff movements .

The only change to what was before are:

1. new Indian GP200 box
2. new Indian 47 crown wheel and BGM 18 front sprocket and chain to suit
3. removed the centre leg in the clutch basket so it would fit gp200 box.
4. new clutch (tried new MB springs but seemed to strong so put originals back in)

anyone seen this before or any ideas? reading similar posts it seems I may need to look at the selector end of things,maybe Spanish/Indian mismatch?

It only has 4000 kms on it so did not think i ended to change anything else

Thanks
Dean

[holty]

I've had a couple of problems with gp Indian gearboxes, one was caused by the selector that my customer supplied was machined incorrectly so it wasn't engaging the gear all the way, I simply replaced it with one from af rayspeed and I was fine, next one was caused by the gear stack being a bit to low for the layshaft, check your stack is higher, I measured the gears and found 4th was to thin, replaced that with a genuine sil gear and problem solved, as most people know Indian parts can be of very poor quality although genuine soil seem to be fine.
When you had built it up did you put it into each gear and turnover by hand to check for any binding or tight spots ?

[HxPaul]

When you fitted the spider and tightened it up,could you turn it by hand ? 0.003 thou is at the very bottom of the clearance (0.003 to 0.011 thou)

[swissdean]

Thanks both, i did check gear stack sat above layshaft..i think it needs 1mm or so from memory, but was fine and I agree .003 is bottom end but it turned fine by hand.. and i saw on MBs website he says go as tight as you can.

i have another GP200 box, may take it all apart again and try that one, not sure where the 'new one' came from ie cheap Indian or quality part, it seemed fine

Thanks for the swift replies

[dickie]

New gears but original spider?
Could be that the dogs on the spider are a bit big for the new gears?
Might be worth fettling the edges of the new gears so that the dogs slip in easily.

Thinking right outside the box (pun intended); did you fit a new speedo at the same time? I once found changing gear a nightmare after doing this. It was due to the brass roller rubbing on it as it had a slightly larger form than the original.

[roli150lam]

I had similar recently,the problem was at the headset end.I had to dismantle the and clean 50 years of crud from the handlebar tube.Co-incidentally that came following a gearbox rebuild.Dis-connect the gear cables see if it moves freely.

[coaster]

I had similar recently with a new engine build it which turned out to be the gear selector arm catching on the rear brake cable, worth checking.