Hi all,
I picked up a 70 steel tanker locally last Sept and am finally getting around to bringing it back to life. Now that it's running, I've discovered it's got some shifting issues that I'm trying to resolve (yeah....like that's never happened on a Sachs engine). Once I removed the clutch cover and clutch, I discovered that the shift pawl spring was broken which is certainly a problem. I have removed the shift mechanism from the engine to replace the broken spring but Its been awhile since I've had one of these out. I can't remember if there is supposed to be a shim/shims between the shift mechanism and the engine case and hope someone can refresh my memory on this. In the parts breakdown manual, its shim item # 24 with part number 0244 055 000 that's in question here. I can't remember if this shim goes on the inside of the engine case or outside of the case under the shift mechanism. My main reason for asking is because before I took the mechanism out I laid a straight edge across the engine cases (without the gasket) to check and ensure the shims on outer end of the mechanism were flush with the engine case as it shows in the rebuild manual. The shims were not flush and so started to wonder if something was mistakenly left out of the shift mechanism assembly build up at one time. Any help would be greatly appreciated ! Thanks !
Dave McC
Hi Dave, this is definitely a common occurrence for motors that have been played with over the years. Using your straight edge, the shims need to be flush with the case edge without the case gasket but not binding when you reinstall the gasket and cover. You usually need shims on both sides of the circlip to accomplish this. Page 51 and 52 covers this in the owners manual. I can email you a scan of this if you need a copy. - Cal
Hi Cal,
Thanks for the reply, Yes, I have the owner's manual and you are correct that fig.112 on page 51 is my concern when placing a straight edge across the case to check the height of the assembly when installed in the engine. I have a pair of shims under the circlip and a single shim above the circlip and it's still below flush with engine case and so this needs to be corrected along with the broken pawl spring. As I recall, most of the bikes I've had apart usually only have a single shim on top of the circlip and so am trying to figure out where a shim could be missing in the assembly. Could be missing between the shift mechanism and the engine case if one is needed there because everything else looks to be correct. The parts manual exploded view picture of the shift assembly shows shims between the shift mechanism and the starter gear and can't remember if those are on the inside or outside of the engine case. If there are supposed to be shims between the mechanism and the engine case then mine are missing and this could be giving me the discrepancy with the straight edge. Let me know what you think. Thanks again.
Dave McC
I think your on the right track. Most Sachs motors that I've rebuild have only one shim above the circlip. A few motors especially the older ones had up to three of various thicknesses however. As you say you may be missing one between the shifting mechanisum and the engine case. The shims you mention between the shift mechanism should be placed on the outside of the case so they rest against the base of the selector shaft. The only one on the inside of the case is under the starter gear. I hope you don't have to split the cases to get it right. Best of Luck!
- Cal
Cal,
Thanks for the help. As it turns out, the pair of thin shims (0244 055 000) I originally inquired about between the selector mechanism and engine case were definitely missing. Once I found some and put them in, the straight edge check was now good with only a single shim above the circlip. Installed a good pawl spring and then tweaked the adjustment on the selector arm. Happy to report that after putting everything back together today, I fired the bike up and took it for a ride and it shifts fine now. Thanks again for the help !
Dave McC
Great news Dave, glad that's all it was. Time to go riding :D