Pressing new bushings into the mainshaft sleeve gear

Years ago on a bike trip I bought a very large C clamp to break a tire bead off a rim after my buddy's beamer had picked up a nail. I almost chucked it out a few months ago, but it came in handy as a bushing press. After I found a washer that nicely caught the bushing edge and chased the first old one in about 1/4", I used two new bushings to push the old ones out, then pushed in the best of the two old ones to wind up with three bushings in place. The old one ended up at the gear end which was still fairly tight. Most of the slop was on the outboard end where the sprocket and clutch basket seem to do their worst. My shaft has suffered some wear, but I wound up with a nice turning clearance, about .002". This worked really well and might be handy for those who don't have a proper press.
My project is moving ahead with the speed of a racing glacier....

But a Glacier like the tortoise gets to the end !

Eventually

kommando said:

But a Glacier like the tortoise gets to the end !

Eventually

Click to expand...

I've frozen them and used a socket with extension working/tapping but fast.

Put the circlip back on the mainshaft, if you removed it, but needs to be a good fit; new is better. I use a hydraulic press; push out either end. If you use the mainshaft that you intend to reinstall protect the threaded end that meets the press.

Clean and measure the bore, measure the new bushing(s), make sure that you will end up with a press fit. Freeze the after coating inside and outside with moly grease, alos grease the the bore, press them back in. I like to chamfer the end that enters the sleeve gear.

Best.