I have an 80s vintage Dahon with a S-A AW hub that won't shift into low. I have disassembled and degunked the insides, and the guts seemed to be moving smoothly. Even with the shifter cable tightened enough so that the hub barely makes it into 3rd, something is preventing the cable from pulling the insides all the way into low, I can't even move the shifter all the way into the 1st gear position.

The amount of chain travel between these two positions is about two indicator chain links' worth: In 3rd, with the cable fully slack, there are about three indicator chain pins showing out of the axle, and with cable as tight as it will go (the hub still in 2nd), there are 5 chain pins showing.

About the only adjustment I have not fiddled with is the right hand bearing cone adjustment. Perhaps it is tightened too much? I checked it today when I disassembled the hub, and it was at the "recommended" setting, backed out about 1/2 - 3/4 turn from finger tight.

TIA, ---wsanders

This is some kind of problem with the shifter or cable. I can shift into all three gears on the bench, but on the bike it jams between 2nd and 1st. Maybe I'll try to replace the indicator chain ....

Make sure your cable is not kinked or binding. The base adjustment for the indicator chain is having the shoulder even with the end of the axle in second gear, then adjust as necessary from there. Has the indicator chain been replaced before and if so is it the correct one? I have had the problem a couple of times on older hubs. IIRC there are 3 different lengths based on overall axle length.

Aaron

Make sure that the indicator is not bottomed out when threaded in. Spin it about 1/2-turn backwards before threading on the shifter cable.

Shift into low. Grab the cable and manually pull it out. If it goes into low, something is to long. If so, try taking up the slack with the cable wheel

Something else to consider: I was having a similar problem yesterday, and discovered the trigger shifter itself had an issue - the small plate held by the spring was broken and not holding the cable when trying to shift into low. This appears like an issue engaging low, when in fact low was getting engaged but the shifter couldn't hold the cable and it would immediately snap back to 2nd.

A new (used) trigger ($10) fixed that right away.

Mark

One thing I'm not getting is if the hub did work fine at one point and now does not. If it came to you with a problem, one issue might be that you have the wrong-sized indicator. They came in a bunch of different lengths (i.e., from the threaded portion to where the chain starts), at least based on the collection I've amassed in my parts drawer.

Neal

Thanks to all who replied. I now have first gear, but I have the RH bearing cone backed out a full turn, a little bit further than the must-never-exceed 5/8 turn specified. It is still hard to shift into low, but it seems to get a little bit easier each time I shift. This weekend, after I get hold of an thin 15mm box-end wrench so I can align the cones more precisely, I'll back the RH cone in 1/4 turn and see what happens.

The indicator chain is in OK shape - it's screwed all the way in and then backed out about 3/4 turn (you need to back it out so the chain can align itself and you don't pull the chain sideways.)

Another thing that was impinging on reaching first gear is that the shifter was too close to the brake lever, and the band holding the brake lever on was preventing the shifter lever from going all the way down to the handlebar where it needs to be to reach 1st. The total travel is still less than three indicator chain pins.