obscure gearbox questions

The inner gb cover has a steel bushing pressed in that supports the kickstart shaft. I have a case from a MK3 and the bushing sits proud of the case on the inboard side. It is approx .020 taller than the case. Should it be flush? This will make a difference on the shimming. The only reason I can see is that possibly the KS shaft should bear on the steel bushing instead of the alu case.

#2...recommended free play of the KS shaft?

#3...The steel bushing has a very large bevel on the inboard side. Why this much instead of a slight bevel to ease assembly?

I just checked my Mk III inner gearbox cover. The steel bushing sits very slightly proud of the aluminum casting. Height varies depending on where I measure. Anywhere from .007" to .012"

Free play only exists if you are using a roller bearing on the left side of the lay-shaft. Generally .005" to .020" is desired with the roller bearing. Some members express a fear that .005" is to little. However, the gearbox case and covers are aluminum, but the shafts and gears are steel. So as the gearbox heats up, the free play will increase, not decrease.

OK. I won't worry about the steel bush. Any ideas about the large bevel?

seattle##gs said:

#3...The steel bushing has a very large bevel on the inboard side. Why this much instead of a slight bevel to ease assembly?

Click to expand...

I don't know but it's normal.