in the bush should be forced round into the
second or third slot beyond its free position.
51.
REMOVAL
OF
GEARS.
If
the clutch has been removed,
it
will be
necessary to fit a
shon
length of tubing over
~e
end of the main axle and hold
it
in
place
with a clutch
nut
to retain the axle in position
whilst the gears are being removed.
Remove end cover. (Paras. 44 and 47).
Remove the low gear and
kick
staner wheel
the large gear on the layshaft which has a
bronze bush pressed into its centre.
Remove the small wheel from the end of
the main axle.
Remove the mainshaft second gear; this is
fitted with a fully floating bush. Unscrew the
striker fork shaft by means of the two flats
machined on its outer end and remove
it
together with the layshaft second gear and the
striker fork.
Remove the tubular distance piece or clutch
and withdraw the main axle together with the
third gear and striker fork.
The
bore of the main gear wheel, which still
remains
in
position, carries I 3 rollers which
should be retained in position by inserting
a roll of stiff paper
in
place of the
main
axle
now removed.
The
axle will bring with
it
the
bronze clutch thrust washer which should be
examinP-d,
and
if
there are no grooves visible
across the face which rubs on the main gear
wheel,
it
should be renewed. Withdraw the
layshaft and the two remaining gears, which
will expose the outer race of the layshaft roller
bearing
in
the far end of the box.
The
inner
race with rollers and cage will most probably
come
away
with the layshaft.
The
outer race
may be removed
by
gently heating the case
and dropping
it-joint
face downwards on the
bench or a wooden block.
Remove axle sprocket
nut
which has a left
hand thread and is held with a locking washer
and screw, and withdraw the main gearwheel.
If
the gearbox is
in
the frame and the rear
chain
in
position, obtain assistance to hold the
rear wheel whilst the
nut
is being removed.
If the gearbox is removed from the frame,
the sprocket may
be
held by passing a length
~f ol~ chain around
it
and holding the ends
1D a
VlCe.
Examine the steel roller retaining washer
and
if
it
is badly scored or wom down,
it
should be renewed.
The
main
gear wheel
bearing may be drifted from the shell.
Remember that there is a pen steel washer
fitted either side of
this bearing.
22
52.
REMOVAL
OF
CAM
PLATE.
Remove the domed hexagon
nut
from
beneath the forward eide of the gearbox. This
contains the cam plate indexing plunger which
will drop
out
when the
nut
is removed.
~emove the
~<?
bolts fitted with spring and
plam washers
v1S1ble
on the forward side of
the gearbox shell. These secure the cam plate
and cam plate quadrant, both of which may be
pushed through into the box when the bolts
are removed. Both cam plate and quadrant are
carried in a bronze bush.
It
is unlikely that
these bushes will ever require renewing,
but
they may be readily pressed or drifted out
should the necessity arise.
53.
FITTING
CAM
PLATE.
Place the quadrant in position and secure
it
with its bolt and washers. Place the cam
plate in position so that one of the end grooves
in
its circumference is across the centre of the
indexing plunger hole
in
the gearbox shell
and meshing its gear with the last tooth
but
one on the quadrant, ensuring that the correct
end of the quadrant rack is being used.
Assemble the positive mechanism on to the
inner cover (Para.
50
).
Place cover
in
position
and correct quadrant lever to ratchet
by
means
knuckle pin. (Para 46).
Set positive footchange to top gear and
~eek
that the indexing plunger groove lies
1Jl the correct position to mesh with the index-
ing plunger when fitted. Withdraw cam plate
and re-mesh as necessary until the correct
position is obtained when the cam plate bolts
and washers should be fitted and tightened.
Fit
indexing plunger, spring and plunger bush.
54.
PfITING
GEARS
INTO
GEARBOX.
Drop pen steel washer ( the smaller of the
two) into the bottom of the bearing housing
before pressing
in
the bearing.
Fit
main gear
wheel bearing and layshaft bearing outer race.
Fit
rollers (13) to main gear wheel smearing
the assembly with grease, and insert the paper
tube to retain the rollers.
Fit
large pen steel washer over the shank
~f !he
m~
gear wheel, press the wheel home
m
1ts
bearmg, fit gearbox axle sprocket, tighten
the nut, fit locking washer and pin.
Fit
bronze clutch thrust washer to main
axle so that the face having the three oil
grooves will be against the main gear wheel.
Carefully remove the paper tube from the main
gear and insert main axle into position.
Fit
distance tube
in
place of clutch and
add clutch nut.
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