Topic: Sloppy shifter

[eigenvector]

Possibly, it would make it easier to assemble everything.

In any event I'll replace the screw - the one that's there is barnacled with rust anyway.  It's a 4x8 pan screw - so that's about 5/16" long, certainly longer than the one there now.

[eigenvector]

Survey says....

Alignment hole.

The screw does not penetrate into the shifter mechanism - it's just there to plug a hole in the cover, so that you can ensure the shifter and shifter selector are properly aligned when the cover is assembled.

[eigenvector]

Well for what it's worth I think I've finally run down why the shifting on this bike is so sloppy.

The drum shifter - that is the device which physically rotates the shift drum has a very loose fit.

The drum shifter is connected to the shift drum with 2 spring loaded pawls - those pawls are what contact the shift drum and rotate it.  See the image - they're parts 10, 11, and 12.

The connection between the pawls and the shift drum is simply very sloppy - even with brand new pawls.  The shift drum isn't worn out, the pawls are too thin. 

But here's what I think was actually happening for me to have missed all those shifts.  If the shifter shaft is pulled out even a very small amount the drum shifter will no longer contact the shift pedal and it simply won't shift.  Basically the gears will no longer be in contact and you can pull up on that shifter all you want - the actual drum shifter won't rotate.  It's what I think was happening in my case.  So my real solution here is to find a way to get that shift shaft as solid in there as it can get - no in and out motion.

[Gene]

Interesting. So the shaft is actually a little short.

[eigenvector]

Or you could say the cover is a little too roomy.   

I think what I'll try - maybe, is putting a washer between the shift shaft and the cage bearing that forms the oil seal.  That should push the shift shaft in, or at least remove the in-out slack that it has now.

I was shocked at how little movement was required before the gears fell out of contact.  The gear itself is less than 1/4" wide and even then it's not fully contacting the drum shifter.