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Old 12-09-17, 07:06 AM
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If you say that you are having difficulty pulling the indicator chain sometimes, it's entirely possible that it is worn/chewed up enough that it no longer slides freely over the axle nut. If there are no other obvious impediments (fulcrum/pulley, damaged housing, kinked cable, etc), I would turn my attention to the indicator rod, then to the inside of the hub.

Depending on the length of the rod you have (if it is even original), you can easily find replacements. When they are there right length, you can line the end of the rod (the machined shoulder) up with the end of the axle in second gear, and the hub will operate correctly. If you don't already know, don't screw it in tight; finger tight, then
backed off
until the chain travel lines up with the cable.
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