THE PAWL SPRING: This is the first item to suspect if you attempt to change gear and the lever has no
effect or apparent connection into the box. The spring quite often wears and breaks (carry a spare one)
and when you replace it with a new one you will more than likely have it) 'set' the spring as follows to
ensure a good gear change: with the outer gearbox cover in your hand and the lever mechanism and
ratchet assembled the pawl spring must sit on its rest plate (part of gear lever stop plate) it must then
either just touch or just clear the pawl with its double cranked leg downward. Most important with the
pawl central in the pawl spring an imaginary line through the centre of the pawl must be at right singles to
the centre of its operating arm. This only has to be a fraction out for a poor gear change, either up or
down to result.
To check you have got it right, replace gearbox cover and lever. Put machine on its centre stand and a
block so that the rear wheel is off the ground, then rotate the wheel until a position of the gears can he
found when you can change through most of the gears with the rear wheel anti gears stationary. Now,
starting at 1st gear, select 2nd carefully and as the gear lever returns to its neutral position a click should
be heard (pawl selecting next ratchet). Repeat this through the gears although no click will he heard from
third to fourth as there is no gear after fourth. Repeat this changing down, a click will he heard each time
a change is made and there is another gear to follow.
If you get this result one way only then you have a bias in the pawl spring and it will have to be set slightly
the other way.
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