ASSEMBLING
THE
GEARBOX
Mainshaft Gears.
Secure the gearbox casing in a vertical position with the open
end facing upwards (See Fig.
26).
Slide the mainshaft third gear over the mainshaft
followed by the mainshaft second gsar, with their selector grooves towards the centre.
Grease the camplate roller and
fit
it
onto the smaller selector fork peg. Position
the smaller selector fork in the second and third gear grooves with the shaft of the
selector fork below the mainshaft and the roller towards the clutch end of the casing.
Lower the assembly into the case. When the gear cluster
is
correctly located, turn
the selector fork until the camplate roller rests in the selector campiate track.
Withdraw the mainshaft slowly, leaving the second and third gears and selector fork
in position to assist assembly of the layshaft gears.
Layshaft Gears. Assemble the third and second gear with the selector fork
grooves facing inwards to tbe layshaft and high gear.
Apply grease to the roller
and
fit
to the larger selector fork peg.
Fit the larger selector fork into the grooves,
with
the shaft of the selector above the iayshaft and the camplate roller towards the
open end of the gearbox. Lubricate the layshaft bush and lightly smear the shaft
with oil. Lower the layshaf: assembly into the gearbox, small gear first, until the
camplate roller can be engaged on the camplate track. Oil the selector rod and
thread
it
very carefully through the selector forks, shoulder end first, and engage
it
in the locating hole in the clutch end of the casing. Oil the mainshaft and thread
it
through the rnainshaft gears. Place the layshaft low gear over the layshaft end
with
the inrernal teeth facing inwards. Piace a strzight edge over the gearbox end
and test the clearance between the running face of the layshaft low gear and the
outer face of the inner casing. Minimum allowable clearance
is
0.005"
(0.13
mm.).
If the clearance is less than specified, the layshaft bush cannot have been fully located,
or, if
it
has, the face of the bush must be cleaned up. Remember that a layshaft
seizure means a locked rear wheel.
Gearbox Inner Cover. Fit the hollow dowels and long casing studs to the casing
and lightly smear jointing compound onto the cover inner face. With the selector
quadrant held in the high (4th) gear position, assemble the inner cover to the casing.
Tighten the casing screws
;
do not omit the screw adjacent to the selector quadrant
Inside the cover. The action of the seiector assembly can be checked if the qurdrant
is
operated by a screwdriver and the high gear and mainshaft are rotated at the same
time. Gear selection should be correct if these instructions have been carried out
correctly.
With the selector in high gear,
fit
the kickstarter ratchet and pinion assembly onto
the mainshaft in the following order: plain washer, sleeve, spring, pinion with ratchet
face facing outwards, ratchet, lockwasher and nut. Lock the gears by placing
a
block
between the chain sprocket and the vice and tighten up the ratchet nut. Bend the
locking washer tab over when the nut is tight.
Gearbox Outer Cover. Smear jointing compound onto the face of the inner cover.
Grasp the gearchange pedal in one hand and the kickstart lever in the other. Wind
the kickstart pedal anti-clockwizr to prevent the quadrant fouling the stop on the
inner cover, when the ouler :aver is slid into position. Fit and tighten up the nuts
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