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TOPIC: ABC gear lever retention

ABC gear lever retention 6 months 2 weeks ago #826

  • Jasdane
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Hi
We all know one of the problems with ABCs is their habit of dropping out of gear, especially when you touch the lever with your leg.
To minimise this I have attached a "rare earth magnet" to the lever and another magnet to the change gate so that when in gear the magnets hold it firmly but you are still able to "break" the magnetic pull to change gear.
I did the MK1 on just 4th gear which was very succesfull, and now the MK2 variety is for 2nd & 4th gears.
The only non reversable damage is the screw hole through the gear lever.
I have attached pictures for your interest.
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ABC gear lever retention 6 months 2 weeks ago #827

  • keithsams
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hi are the pawls that keep the gear position at the side of the gearbox ok ?
these can stick with age also i have seen them packed out with a spacer to increase the spring pressure
also i have seen the slots in the gate extended so it is in the correct position for the pawls to locate.
i think this can arise if a gate is not off the original bike as they would have been fettled up at build up. otherwise a good idea but keep away from the traffic light you might get stuck to them
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ABC gear lever retention 6 months 2 weeks ago #828

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Hi
What pawls ?
There is nothing to hold my gear lever in place apart from the gate.

The traffic lights are not too bad but the steel suppliers are a real drag.
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ABC gear lever retention 6 months 2 weeks ago #830

  • keithsams
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each side of the gearbox nearly at the rear next to the joint there is a plug each side,the same size as the drain pug in the crankcases.
if you undo them there should be a spring and pawl inside,you have to remove these to draw the gears out enblock with the rear end plate.
anyway the pawl locks into grooves on the 2 cross shafts that hold the selectors in place.
the spring and pawl may be difficult to remove and i cannot give you an easy way to remove them.
as i said previous i have seen these with a small packer in and the packers seem to be the same so it might be something they did at the works ?
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ABC gear lever retention 6 months 2 weeks ago #831

  • keithsams
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can anyone put a copy of the gear lever forks and selector rods,if not you can purchace a copy of the original book that has a very good exploded view.
you will find them on ebay or british-motorcycle-parts.com
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ABC gear lever retention 6 months 2 weeks ago #832

  • keithsams
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another problem you may have with top gear are the driving dogs
if they are worn they will jump out of gear. you can weld the worn area. but if your magnets do the job then it will save you a lot of work
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ABC gear lever retention 6 months 2 weeks ago #833

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ABC gear lever retention 6 months 1 week ago #834

  • Jasdane
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Hi and thank you for your response. I did reply earlier but it has got lost in the "cloud" ?
When I rebuilt the gearbox the selectors and springs all seemed OK so I just re assembled them. I thought from your comment that there was another selector spring attached to the external gear lever.
When I was doing the gearbox rebuild I did regrind the dogs, on top gear, with a 5 degree undercut. This did help holding it into top gear. However when riding it proved very easy to just touch the gear lever with your leg and it dropped into neutral and the engine revs raced.
So after reading "Les Tavener's" report I saw a need to restrain the lever itself, so I came up with the magnet idea and it seemed to work really well.
So the next thing was to fit a magnet to second gear.
I am contemplating fitting magnets to first and third gear positions but it looks a bit more complicated and they are less of a problem.
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ABC gear lever retention 6 months 1 week ago #835

  • keithsams
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hi sorry about the pawl bit
i have looked in the book and its called a locating plunger
the thing to remember is the the plunger locates the fork in a set position so wharever you do it will be in the same position and if the dogs are worn you will only get part contact and when that happens you will have the problem of gears jumping out
i suppose you can adjust the forks on the spindle because they are threaded and locked on with the nut but not something i have done. remove some material off the selector fork to allow it furher into mess?
all will mean the gearbox coming out i suppose.
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