Gearbox Assembly

Rockyrob · Oct 9, 2008

I am at the point of refitting inner cover and am concerned about the following Can someone tell me if there is an issue or it is normal please, Note the circlip in Pic 1 having about i/4 inch clearance from shoulder which in this position makes the gear sit flush with gearbox shell Pic 2 (seems correct) When i push main shaft back (into gearbox to make circlip sit flush the gear sits out from the shell by the corresponding difference Pic3 , cover fits on and everything seems ok but i dont like the look of the circlip gap,Am i missing something here? Thanks as always for the great assistance. , You will note by the gasket goo how confident i was feeling at the time

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79x100 · Oct 9, 2008

The circlip is for locating the clutch on the mainshaft (don't forget the collar that sits over it) so it shouldn't be tight against the sleeve gear. It all looks OK to me.

Mainshaft location is fixed by the nut on the inner cover.

Rockyrob · Oct 9, 2008

Thats a relief, Many thanks for the prompt reply. I,m from the school of rip it apart and when you put it back together look in the bowl and see whats left. The collar you mentioned, Whats it look like, ? I remember a couple of shims and a stainless flat washer falling on the floor when i pulled the basket off. I assume it is the washer??

dave M · Oct 9, 2008

79X100 is absolutely right about the shaft position being set by the nut which secures it to the bearing in the inner cover, the collar that he is refering to looks like a thick washer with a recess on one side to accomodate the circlip. There are then shims that go between this washer and the clutch hub, the function of these is to allow the clutch hub position to be varied in order to align the primary drive chain.

Rockyrob · Oct 9, 2008

Great work guys thanks heaps, with the knowledge i get from here i will be back on the road in no time.

Stuart SS · Oct 10, 2008

OH bloke.. you are going :shock: to be in the Pooh here!!

TROUBLE!!! ~ oh deary me !! :shock: :shock:

When "Mum" sees that cutting board you are going to be in for a real ear bashing!!! You poor bugger !!!

GOOD Luk you are going to need it ~ !!!

Try distracting to a perfect investment op !!

http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... escription

grandpaul · Oct 10, 2008

Stuart, too cold for good riding in Iceland.

Hortons Norton · Oct 10, 2008

Not with your girl on the back and spiked tires!

cash · Oct 10, 2008

Hortons Norton said:
Not with your girl on the back and spiked tires!

Says him from California, lucky sod.

Cash :wink:

79x100 · Oct 10, 2008

Rockyrob said:
Thats a relief, Many thanks for the prompt reply. I,m from the school of rip it apart and when you put it back together look in the bowl and see whats left.

How's the box coming together then ? The fact that you're collecting the parts in a bowl suggests you're not doing too badly as most of them are designed to stick to another component and then bounce as far as possible.

If I could make one comment, I might venture to suggest that you are using quite a lot of goo on the gaskets. If your faces are halfway flat and no burrs round the studs, you should be able to get away with just a smear of oil on the OE gaskets- they're quite good quality and the face has plenty of fasteners. There's no pressure inside either.

79x100 · Oct 10, 2008

ludwig said:
"I might venture to suggest that you are using quite a lot of goo on the gaskets " (quote ) ... exactly what I tought ( but was too shy or too polite to tell ) . you really don't need that orange stuff , but I guess it won't hurt either ..

The chap asked for advice and English is a very polite language. It's a little bit more difficult to give advice in Dutch without sounding like a pushy Hollander

By the way Ludwig, was that your Commando-engined Hybrid at Leuven the other week ? Didn't see the owner or I'd have said hello.

Rockyrob · Oct 11, 2008

Was just following old britts instructions with the goo , that and the fact that the smell of it gives a niceame fuzzy buzz, box is back together, all gears are easy to select by hand, lot of end play in the kick shaft, to shim it out to the extent of negating it makes the pawl thing miss the catch thingy, sorry its late and i cant explain better,

Back in bike tomorrow , then wait a few days for polished outer cases to return and back on the road, will advise or gearbox rebuild sucess/ failure then

PS I got the cutting board back before she noticed Stuart,besides it was a trade off for not heating the cases in the oven. i used a propane tortch

Gearbox Assembly

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