4.6 Foot Gear Shift Lever Adjusting

Gear shift is realized by applying foot gear shift lever or hand gear shife lever. If trip stop happens in operation by applying foot gear shift lever, hand gear shift lever can be used to shift the gear to proper position . If trip stop still exists after using hand gear shift lever, joint sleeve , driving fork and sector plate should be repaired or replaced . If trip stop disappears after using hand gear shift lever, the cause is that the foot gear shift lever is not properly adjusted.
Then adjust it as follows:

4. 6.1 If trip-under stop happens in shifting from lower to higher gear position, screw out the lower adjusting screw (Item 2 In Fig.12).



4.6.2 If trip-over stop happens in shifting from lower to higher gear position , screw in the lower adjusting screw.

4.6.3 If trip-under stop happens in shifting from higher to lower gear position, screw out the upper adjusting screw (Item1 in Fig.12).

4.6.4 If trip-over stop happens in shifting from higher to lower gear position, screw in the upper adjusting screw.

Richard's translation:

Gear shifting is accomplished by applying either the foot gear shift lever or the hand gear shift lever.

If a false neutral happens in operation by using the foot shifter, the hand shift lever can be used to shift the gears. It may also be used to test the foot shifter. If you cannot use the hand shifter to select gears the joint sleeve, driving fork or sector plate should be repaired or replaced.

If the false neutral disappears after using the hand lever the problem is an improperly adjusted foot shifter.

Proper adjustment

The foot lever must be set to move the gear to very near the center of its mating gear. If the lever does not move the gear you are shifting far enough it will pop back into a false neutral. If the foot lever is set to move too far the transmission will pass the proper contact point and find a neutral on the other side of the gear you are selecting. Since the gear alignment will vary a bit from gear to gear you are trying to find the best compromise in foot gear lever movement that allows proper meshing of all gear sets. If you need a gear to move further you loosen the adjustment screw for that direction of shifting. If it moves too far you tighten the screw. The upper screw controls downshifting. The lower screw controls up shifting.

For example If the bike slips out of gear while downshifting the upper screw must be adjusted to center the gear. If it has slipped back toward the higher gear you shifted out of, (judging by the hand lever) loosen the adjusting screw. If it has moved past the gear you were selecting tighten the upper screw so that the gear does not move as far.

Below is a rough translation from the CJ manual.

Adjust as follows: (Section 4. 6.1)

Lower adjusting screw

If the problem is in shifting from a lower to a higher gear position and the movement is not far enough to fully engage the higher gear, screw out the lower adjusting screw (Item 4 in Fig.12 (Section 4.6.2)

If a false neutral occurs while shifting from a lower to a higher gear position, resulting in the hand lever passing the gear, screw in the lower adjusting screw.
(Section 4.6.3)

Upper adjusting screw

If the false neutral occurs while shifting from a higher to a lower gear position, and the hand lever ends up between the higher and lower gear, loosen the upper adjusting screw (Item 3 in Fig.12). (Section 4.6.4)

If the false neutral occurs while shifting from a higher to a lower gear position and the hand lever ends up past the lower gear you were attempting to select, screw in the upper adjusting screw.

Hold the screw with a screwdriver to keep it from turning when you loosen or tighten the locknut.

Keep a record of where you started and make adjustments in quarter turn increments.