AJS & Matchless Owners Club

BigJock wrote:BTW lost the clutch because oil level had dropped and the pull lever inside rh cover had locked up.

Don't let the oil level drop keep it right up to the filler/clutch arm plate otherwise you will knacker the box as all the gear are in the top section of the box

Got it back together - thread n superglue. Worked in all 4 gears but rattling in neutral then bang...kickstart jumps rattling like blazes and no gears - anyone????

You need to take the cover off again and have a look. Broken pawl spring?

Ozmadman wrote:

BigJock wrote:BTW lost the clutch because oil level had dropped and the pull lever inside rh cover had locked up.

Don't let the oil level drop keep it right up to the filler/clutch arm plate otherwise you will knacker the box as all the gear are in the top section of the box

Hopefully they still are.

BigJock wrote:Got it back together - thread n superglue. Worked in all 4 gears but rattling in neutral then bang...kickstart jumps rattling like blazes and no gears - anyone????

Praying for you that nothing serious has happened.

Cover been off 5 times now. All mechanical parts are good. Have had to shim selector rod 3mm between rod arm internal and os cover - only way the pawl will fully contact the ratchet. When cover off the box will select all gears when assyd wil drop into 1 or 2 but not come out again and no the shaft is not binding

It's a bit worrying if you have a extra shim on the gear-side (inside) of the selector shaft. Wouldn't that mess up the selector alignment?
Does it have the correct spacer washer on the pawl side (outside)? It should look like this:
https://www.ifixit.com/Guide/AJS-Matchl ... 77#s172053

The spacers are on rh side behind selector are mechaism and spacers under 2 mounting bolts for spring retainer. Pawl now aligns with ratchet...more on that later. Another strange thing is solid selector shaft has no grooves for o rings so wjen fitted inside selector tune there is nothing to stop oil running out of box......The box now selects all gears but when in neutral with cluch out you can hear gears chattering away like a bad shift but pull in cluch and sound goes away. Anyone????

Something is definitely wrong there?? you should have two small grooves on that shaft, no wonder oil is pouring out. As for the gears chattering it has to be the issue you have with the extra shims on the selector shaft that is causing the gears not to clear each other completely when neutral is selected, presuming it isn't just the kick start ratchet not clearing properly due to not enough tension on the return spring??

Very strange - and it seems you're not alone. red_dog49 is trying to get his gearbox together at the moment and he's got the exact same issue with the selector pawl not meshing properly.
I'll take a look at a spare 'box this evening to see if there's anything obvious...

I had a look and couldn't see anything obvious that would cause the selector to fail to engage with the pawl.
Perhaps one of these photos will help?