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[Norm]

Stef, I didn't suggest breaking the nut, just hitting it with the hammer and chisel to get it starting to undo, trying to split it could do too much damage, it must have been put on with Loctite for it to be this tight. As for the forks sounds like you will have to remove the pinch bolts in the lower yoke and hammer a thin chisel/screwdriver in the slot to spread the yoke just a fraction. Have the tubes been painted inside the headlight shell, this causes problems

[stefaand]

Hey Norm,
they haven't been painted on the inside no. They do spin freely inside the lower yoke though, even when I twist the fork bottoms. I've removed the pinch bolts a long time ago to get the little plate off. It appears to me as if though the bike has been repainted at some point, unless royal enfield didnt use a primer.
I don't really think the PO used loctight as he let the primary chain saw into the cases...I'm reluctant to mount the whole thing back into the frame only to use the raggedy chain to create enough torque to remove the nut..Heading over to a friends house tomorrow. His father is more equipped and can probably help me out.

I've noticed theres a hole at the top of the gearbox as well, at the mounting point closest to the gearshift mechanism. It doesn't look like wear damage, but rather like factory..is this unusual?

[Norm]

Stef, not sure what you mean about the hole in the box but it doesn't sound right, is it in the actual gearbox housing or is it in the end cover, and when I say the end cover that is the cover which holds the gearshift bits. No chance you are thinking about where the clutch cable enters the end cover?

[stefaand]

No, I mean the actual gearbox casing. It has two 'tunnels' trough which the two studs run which attach the gearbox to the frame. The 'tunnel' closest to the gearshift side's bottom is open. I'll try get a picture tomorrow.

[stefaand]

http://i.ebayimg.com/00/s/NjAwWDgwMA==/ ... v/$_57.JPG

In this picture you can see the two holes where the gear selector is supposed to be mounted to an axle on the top (bottom of picture). Right above (below on picture) is a mounting stud for the gearbox to the frame. Right there in the middle it looks like its rubbed trough..

[Norm]

Stef, I haven't tried to look at the pics but I assume you are talking about missing alloy under the 2 east west studs across the top of the box. If so just bad casting, seen it before, doesn't seem to cause any problems, maybe a slight leak at the top around the triangles but no big deal. Not much you can do about it, maybe JBWeld a bit of half tube onto it to seal up the hole, there is plenty of clearance up there so it won't foul on anything

[stefaand]

Thanks norm, that's exactly what I meant. I was thinking of just putting O-rings on the studs instead, but I'll try to get my hands on some JB weld.

[The rider formaly known as Lone Rider]

You may have it removed by now, but I had a similar problem.

Got an old chain, wound it around the sprocket several times until it locked against the box casing. Large socket and wrench. Job done.

Other than that, out with the Dremil.

[Norm]

Stef, you will never got "O" rings in there, it is hard enough just to get the nuts on

[stefaand]

You are right norm; I will tackle this when I get to it. Ill have to get the middle gearbox cover welded because a piece has broken off, but I don't know a welder so I will have to dig around for some reputation..

It looks like the front fork is stuck in the metal rings just above the bottom yoke..They are painted on the inside. I guess I'll have to heat those rings to get the tubes out.

thankgod this is an enfield. my shopping cart is nearly only essentials and I've already reached my max budget, can't imagine what this would have been like if it was a sunbeam or something..