A65R gearbox getting nowhere

[Cmcl.1959]

Hi to all,
As a follow up to my previous posts about the gear change issues with my 1964 A65R, I now have the gearbox out of the bike. I managed to get a couple of new parts, namely shifting forks, plunger and spring and a new camplate from Holland.
The dogs on both sliding gears are a bit worn but replacements are hard to get and the only ones I've seen are overseas again and very expensive.
When tried with the new parts with the cassette in the vice I can get the gears but it's not easy.
When I reinstall it in the bike it's very difficult to get any gear especially 1st.
Anyway I've added a photo of the camplate as it's pictured in the workshop manual alongside the old camplate and the new one.
I'm not sure if the old one has been filed or if it's wear in the tracks as the tracks on the new one are much straighter.
I'm reluctant to try modifying the new one as it was really difficult to get hold of.
Any feedback would be gratefully received.
Regards
Clarke

[DAVE BRADY]

Hi,

The original ones do look like they have been modified but I reckon that is how they were.
If the rollers on your new selectors move freely in the slots when out of the box then they should be fine. Perhaps polishing the slots may help but the rollers are meant to do just that. The edge of the plate can also be polished a bit to help the plunger slide more easily.
When in the bike you are pushing against the plunger spring and some people suggest shortening the spring a bit. Also, gear boxes work better when turning.  Not easy to simulate on the bench.
Have you tried it with the gear lever fitted?

Dave.

[Cmcl.1959]

Hi Dave,
No I haven't tried with the gear lever.
Before I took it out and the clutch was still on it could move ( with the old camplate) a bit sticky in places but I checked the end float on the lay shaft and it was pretty big and I thought that might not help so I bought the next size up thrust washer and I checked it today with a dti and it's about 4 thou so a lot better.
I might give the camplate a going over with some wet and dry to see how that goes and try again.
Thanks again for the advice.
Regards
Clarke