Drsrnontling Gearbox
Rear
Engine
Plate Studs. Slacken the nuts on the front lower studs and remove
all other nuts from the right hand engine plate. (The gearbox adjuster can be left
in position). Remove the studs by drifting with an aluminium rod.
Remove the
cover plate, slacken the pivot bolt and ease the gearbox back, when both plates can
be removed.
Pivot Bolt.
Remove the nut and withdraw the pivot bolt. The gearbox can now
be taken out of the frame.
DISMANTLING
THE
GEARBOX
Before attempting to dismantle the gearbox, wash it thoroughly to remove dirt, oil
and grease, etc. Drain the oil by removing the plug in the rear of the casing. (Note-
on the Models equipped with the swinging arm rear suspension, the drain plug
is
placed at the bottom front of the casing). Place the gearbox in the vice, with the
pivot lug gripped between the jaws.
Gearbox Outer Cover.
Unscrew the five screws and three nuts holding the
outer cover to the inner cover and tap the
ioint gently with a hide hammer, to
break the jointing compound seal. Grip the gearchange lever and kickstarter crank
and withdraw the cover from the gearbox.
Gearbox
Inner Cover. Bend back the tab on the kickstarter ratchet and pinion
lockwasher and, placing a block between the gearbox sprocket and the vice to prevent
the sprocket revolving, undo the securing nut. Withdraw the ratchet and pinion
assembly complete. Remove the four screws securing the inner cover to the shell.
Tap to break the joint seal and remove the cover. Care should be taken to prevent
the contents
of the gearbox from coming away with the inner cover.
Gear Cluster.
Remove the gear selector fork rod. Slide the mainshaft from the
case until the clutch end comes free from the high gear. Taking care not to lose the
rollers from the selector forks, remove the gear clusters from the gearbox in one
assembly. The only gear remaining
is
the high gear which
is
held in position by the
sprocket nut (See page
78).
The gearbox
is
now completely broken down into units and
it
is
proposed to deal
with these units separately in such a way that the fitter can dismantle, averhaul and
re-assemble the major unit assemblies.
By doing the work in this manner the assembly of the gearbox
is
simplified in that
there
is
no sub-assembly to bother about while concentrating on the correct assembly
of the complete unit.
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