Remove gear cluster with mainshaft, layshaft and two striker forks.
The plunger 042835 together with its spring 040045 will remain in the
gear box shell.
Removing sleeve gear and sprocket. Remove the rear chain. The sleeve
gear sprocket nut 041271 has a left-hand thread. As the sprocket on the
sleeve gear is subject to reversal by accelerating and decelerating the
sprocket nut must be positively tight. In consequence the sprocket 041269
must be firmly held during the process of unscrewing, or tightening the
nut. A chain bar is easy to fabricate. Use a short length of ½" x .305" chain
attached to a bar of suitable length, which is the best medium of holding
the sprocket.
Turn back or flatten the tab washer between the nut and sprocket. Use
a well fitting ring spanner 1½" across the fiats to release the nut.
Removing the sleeve gear. With the sprocket removed, press or gently
tap the gear into the gear box shell.
Removing sleeve gear bearing. Prise out the oil seal, note the way it is
fitted. Use a suitable drift to drive out the roller bearing. The distance
piece 041391 will remain in gear box shell.
Remove bearings from gear box shell. Push out the two metal caps
041394/5 then drift out the layshaft bush 041289 and bush for footchange
spindle 041307.
It is most unlikely that the spindle bush will be affected by wear.
NOTE—The roller bearings for the sleeve gear are self-aligning and can
be waggled about when unsupported by the mainshafts. This can give an
erroneous impression that the bearing is badly worn.
Removing bearing from inner cover. Support firmly the cover and press
out the bush 041299. The kickstarter axle bush 041298 goes into a blind
hole. Screw a coarse thread tap into the bush, and pull out the bush.
There is a peg to locate the clutch body 042141, watch this, when using
a drift to extract the ball bearing 012545 for the mainshaft.
Two oilite bushes 042145 are used for footchange spindle. Carefully
note their location before driving out. An “O” ring 040006 is used
between the outer bush and the cover, which should be discarded before
fitting new hushes.
Removing sleeve gear bushes. Support the gear in a vice (note the loca-
tion of the two bushes), then drift out.
Refitting the bearings. The oilite bushes in the outer cover are made to
size and do not require reaming.
Ream the layshaft bush in gear box .6260" to .6255".
Refitting sleeve gear bushes. These two bushes are thin and somewhat
brittle. Oil the outside diameter of each bush, insert them squarely in the
gear and gently press into position.
Ream both bushes .689" to .688" in. situ.
Refitting the sleeve gear sprocket. The flat side of the sprocket should
face outwards (away from the gear box) see instructions on removing
sprocket nut.
Refitting The oil seal. The metal backing faces outwards. Gently and
squarely tap the oil seal into position.
Assembling the gear box internals. The assembly sequence of the various
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