102 A1 gear change issues

[alexd912]

Hey,

Sorry for these stupid questions and I have been trying to find the answers here but would like to advice.

I have A102 A1 3 speed gearbox and recently the gears were not engaging when the hand change leaver was locking in to place.

I tried adjusting the 2 cables in the box under the bike, but I am not 100% sure how to adjust it and some guidance would be vert helpful.
The cables look very original and one if the adjusters is as far out as it can be from the box and I am starting to wonder if the cables are worn out (stretched).

I found this picture showing what I think are the cable lengths: download/file.php?id=3535&mode=view
I can replace the inner but just trying to understand which image is what cable? I get that its the middle image, but what cable is the left image, and what is the right? OR is it just easier to buy new cables?

Next issue is that I removed clutch leaver to lubricate the cable, but after fitting the leaver back the gear change would not rotate only under very high force!

I can see 2 grub screws holding the gear twist on but I am un sure how to remove it past the handle bar cap.
Can someone advice what I have done wrong.

I found these instructions but it seems to be for a different gear type as its for a 4 speed and my gear leaver is on the underside of the engine.

http://www.heinkeltourist.com/shiftercable.htm

Any help would be very appreciated and if there are any videos or pictures that is always good.


Best regards

Alex

[heinkel-bernd]

Hello Alex,

I wrote this answer in German and then had it translated by GOOGLE.
I hope it is understandable: wink:

Unfortunately there are no assembly instructions for this type 102 A-1, so I do
your question is not "stupid" either: D

The shift cables consist of a cable with two different lengths
Cable sheaths. a brass button is pressed in the middle.
That is why a single shift cable cannot be replaced!
Buy a complete one at the club, hang it up vertically and let it in from both sides
Run in oil (Ballistol Universal Oil I always use) until it drips out at the bottom.

I only edited the sketch for the 102 A-1 three-speed:

What you mean now with the stiffness of the shift lever / clutch lever
unfortunately I do not understand
Can you please explain that in more detail?

I hope I could help you before
Best wishes
Bernd

Hier meine Antwort in Deutsch:

Hallo Alex,

ich habe diese Antwort in Deutsch geschrieben und dann von GOOGLE übersetzen lassen.
Ich hoffe, es ist verständlich

Leider gibt es ja für diesen Typ 102 A-1 keine Montageanleitung, deshalb ich
auch Deine Frage bestimmt nicht "dumm"

Die Schaltzüge bestehen aus einem Seilzug mit zwei verschieden langen
Seilzughüllen. in der Mitte ist ein Messingknopf verpresst.
Darum lässt sich ein einzelner Schaltzug nicht ersetzen !
Kaufe beim Club einen kompletten, hänge ihn senkrecht auf und lass von oben in beide
Züge Öl (Ballistol Universalöl nehme ich immer) hinein laufen, bis es unten heraus tropft.

Ich habe die Skizze nur für den 102 A-1 Dreigang mal etwas bearbeitet:

Was Du jetzt mit der Schwergängigkeit des Schalthebels/Kupplungshebels meinst,
verstehe ich leider nicht
Kannst Du das bitte noch genauer erklären ?

Ich hoffe, ich konnte Dir schon mal helfen,
Viele Grüße
Bernd

[alexd912]

Hallo Bernd

Thank you very much for your reply and it is understandable:)

As said maybe its easier to buy a new cable if I cannot adjust it anymore.

As for hand change I will try again.
After removing the clutch leaver and fitting it back I cannot rotate the gear change anymore. It seems to have got stuck (not the clutch leaver that works fine) and its VERY HARD to turn/rotate to change the gears and I am worried it will break:(

Danke

Alex

[alexd912]

Hey,

Sorry for a late message and now I have a picture of the cable box and just wondering what cable do I need as I can't seem to see the one cable as mentioned.

So I need to get the one cable with the ball in the middle then?

Regards
Alex

[heinkel-bernd]

Yes Alex

Typ 102-A1 Tafel 16 CONTROLS/HANDLEBAR
Pict. 1 Part No 11.1652
Bowdenzug für Schaltung

[alexd912]

Danke.

Alex

[alexd912]

Hey,

BTW How do I take the twist leaver of teh handlebars?
I removed the little screw, but do I need to somehow remove the cap from the end of the handlebars?

Danke

Alex

[heinkel-bernd]

Hi Alex,
.

1 = warm up
2 = inside out
3 = screw

The assembly instructions of the 103 A-0 also apply to the 102 A-1 in many areas :
https://www.heinkel-club.de/t3/ml/download.html

Good luck and

Hier die Übersetzung:
Die Montageanleitung des 103 A-0 gilt in vielen Bereichen auch für den 102 A-1:
https://www.heinkel-club.de/t3/ml/download.html

Viel Glück und

[alexd912]

Hey,

OK that is how it is done.. Lucky I asked as I probably would have broken something..

Regards

Alex

[heinkel-bernd]

Hier die Übersetzung:
Hallo,
OK, so wird es gemacht. Zum Glück habe ich gefragt, da ich wahrscheinlich etwas kaputt gemacht hätte.
Grüße
Alex