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[WannaBRetired]

OK, so I’ve stripped my gearbox and fitted a new layshaft second gear. The mainshaft sliding gear I bought didn’t fit the splines on my shaft and our hosts are investigating this. However, comparison with the new part showed that my mainshaft sliding gear and first gear dogs were not as worn as I thought, so I began to reassemble. Four working gears, good. Turn the back wheel in second gear, RRRRRRRRRRRRRRR. Moving the selector fork slightly reduces this noise. The vibration can actually be felt through the selector fork. All the other gears are fine. So I’ve stripped it all again and can see nothing. The selector fork is oriented as before (could try inverting it?). Layshaft second gear appears to mesh with the sliding gear in first and third as well but no noise there. I’ll have to put it together again very carefully (after I’ve loctited the new output bearing, which looks like it needs some assistance to stay in place) and try again. I have stripped these boxes before with no problem on reassembly. Any suggestions please?

[Alan R]

Oh dear, WannaBRetired,things not going to plan?? First,confession time}--- I've not stripped one of these boxes before BUT, going on what you have just posted----try a rebuild WITHOUT the selector fork (if that's possible ??) and see if the noise is still there. If IT IS then the fault is not related to the fork being there. If it's NOT then the forks presence is the area to search further in. SPOK-LOGIC, Scotty !! Just re-adjusting my cling-on's--- ahhhh ! better.

[WannaBRetired]

Phew! A second rebuild of the gearbox and it seems to be fine now. I've no idea what was wrong the first time. Hopefully I'll have it all finished over the long weekend. Working in a hurry or when tired should definitely be avoided.

[Les H]

Hi looking at the gearbox diagram....http://www.midlandbullets.co.uk/ROYAL%2 ... .......you can see 2nd gear puts the layshaft 3rd gear pinion very near to the layshaft dogs next to it. I reckon that will be where the noise is coming from. If this is the cause, the selector needs to be adjusted so it does not move the gear-sets so close to the kickstart end. Just a possibilty it not the kickstart pawl/ratchet engaging.

[Les H]

CORRECTIOB: Just another possibilty..... it's not the kickstart pawl/ratchet engaging slightly?

[WannaBRetired]

Thanks for the replies. The noise was happening with and without the selector mechanism assembled, using a spanner to select gears - although it did sound a lot like dogs catching. It was also definitely a separate noise to the kickstart pawl engaging. To be honest, I reckon I had assembled something incorrectly, though what it was I've no idea as it does seem difficult to actually get it wrong. Anyway, all is now working and 'silent'.