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[Adrian]

I stand corrected, my apologies. A.

[JTL]

At this stage I'm using grade 800 emery. I'm not sure if grade 1000 or 1200 is needed because the surface left by the 800 is actually much smoother than the one the bronze bush came with. Whatever small particles left after the job I hope a dose of compressed air will remove... But I'm not yet where I want to be regarding tolerance. I have done a little each day for the past 4 days. Any suggestions on how much free play is recommended?

[papasmurf]

This may help:-
http://www.astbearings.com/bushings-and ... ances.html

[Dennis C]

You do not need to use a fine grade Emery, the bush is better with a slightly rough finish as this will a/ reduce the friction area b/ hold oil on the bearing surface.

[JTL]

Papasmurf... this is most helpfull; a nice link to have for future study too. I believe I have reached the right amount of free play at this moment. Dennis... the gearbox will be running with oil, so I hope the surface obtained with grade 800 is not too smooth to hold an oil film. The oil level in the gearbox is above the bush and shaft, so everything is submerged in oil. I guess this should do just fine. All I have to do is to fit the main bearing in the case end and then reassemble the gearcluster and the rest of the gearbox... Jacob

[JTL]

Hi all... an update on my gearbox renovation and an oil question. I have done some 500 km testing the gearbox and the gearchange. Everything seems to work fine. Gearchanging is much better most of the time, but occationally I hit neutrals in between 2'nd and third changing up and between 4'th and third, third and 2'nd changing down. Going from 2'nd to neutral or 1'st to neutral can be done almost at a complete stop (much better now). I have used Castrol D140 gearbox oil, but it's way too thick. Kick starting the bike is a war, so I'm changing this to ST90. Can someone tell me how much oil the gearbox takes? I have used 700ml D140, and it's flowing out the oil level plug when removed. I have been thinking about filling the box with 600ml oil, do some riding and topping up with the oil level plug removed. This way I should be able to hit the right amount of oil. I don't want to fill too much oil into the gearbox, because it's leaking when I use the side stand (no leaking while on center stand). The leaking started after mounting sealed bearings... regards Jacob