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[jawa-enfield]

Hi, 4 speeder with new bearings, bronze bush ist all the way in, Kickstarter bus is reworked and layshaft end goes all the way in. cannot get the cover (not the end cap)on, there's about 3-4mm space between the parts. The obstruction is somewhere on the layshaft..
Installed the close ratio sprocket, also all the way upon the collar,
Can anyone guess what is going wrong?

[Bullet Whisperer]

Did you ensure the kickstart ratchet pawl was fully closed, so it could enter inside the layshaft gear?

[jawa-enfield]

yes..
Could it be difference in gasket thickness?
Even with the layshaft out, it won't close and block the mainshaft

[jawa-enfield]

The kickstart assy looks like this, but sill the pawl rattles in the sprocket.. i do not know why, i did not change the pawl, i did change the sprocket (close-ratio)

[jawa-enfield]

The kickstart assy looks like this, but still the pawl rattles in the sprocket.. i do not know why, i did not change the pawl, i did change the sprocket (close-ratio)
How is this pissible? It has worked with this pawl and assy!

[vince]

Hi, 1. check you have the mainshaft dog the correct way round.2 check the oil thrower is engaged on the mainshaft shoulder. Ensure you have the correct one on the inside of the cover, it should be flush with the gear. Stick it on with grease. 3 the pawl should be flush , it looks like its standing proud. The half moon stop should hold it clear of the ratchet. I would check to see if the new gear has the same clearance as the original. 4. is the layshaft fully engaged at the back of the gearbox. Vince

[jawa-enfield]

The pawl should be 'flat;'? okay.. strange thing is that it worked like this for many years, so i have to make a new dog that presses the pawl further down.,
The layshaft is not 'too long' The problem seems to be the length of the mainshaft, checked position of the roller bearings.
The new layshaft gear had ,10mm smaller inner diameter.

The mainshaft dog is pressed against the shlouder, the oil flinger plate is maximum down, no more space there.
Te oil flinger plate is the sqame it hass ran with for a long time..
I really don't know what is the problem.
Thanks for reacting!

[jawa-enfield]

The only thing i can think of is that the new roller bearings have- despite the same number- different dimensions...
Checked several times if they were secured against their seats.. cannot understand it.

[vince]

Hi, check the inner oil thrower on the mainshaft is correct way round, the recess should face inward and fit over splines. Vince

[jawa-enfield]

Thanks for reply, but it fits only one way? Will check again..