Question for you: what is the approximate throw on the gearbox when everything is adjusted properly?
Mine is the only M20 I've ridden. I've rebuilt my box as best as I could following the manual. My gear selector takes approximately 5 inches to change up. That sure seems excessive. I assume I could accomplish a shorter throw by lengthening the shaft attached to the clevis, is that right?
Hi Kevin, 5" sounds about right fo the gear lever travel.
Adjusting the control rod length will only alter the engagement of the selector dogs not the gear lever travel. If gear selection is good then don't alter the control rod length.
Try looking for wear on the pawl pins and on the plate that it engages with , just a little bit of wear here can result in excessive travel, also maybe someone has ground the ends of the pawls if they looked worn, also check your gear lever is not loose on its splines as just a few thousandths of an inch here could be about half an inch on the end of the lever. Check also the pins on the rod aren't worn and that all the bushes are snug as just a little bit of movement here can also amplify the gear lever travel