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[JTL]

Hi all... I'm about to do a first big service to the gearbox (new kick starter pawl etc.), but have come to a halt. I can't get the inner rachet off it's square shaft. I have a new ratchet (spare part) that just slides on and off the shaft, but the one in the gear selector sits there with a very tight grib. Any advice on how to remove the rachet is most welcome... regards Jacob

[JTL]

Got it off. It was just very reluctant after 35K km in the same place. Anything I should be aware of beside what the tech notes on the subject says before I break the seal on the inner cover?

[Exile]

Glad that you solved the problem. Perhaps you would like to share how you got it removed, that we others might learn something?

[JTL]

Hi Exile... gentle force with a screwdriver made it come loose. I guess old grease had it stick like it was glued.

[Beezabryan]

The gentle application of brute force and a modicum of pig igerrance is often the way forward

[papasmurf]

Itemised bill sent to Falmouth Docks by a contractor:-
To freeing off propeller shaft bearing:- Hitting with hammer £1, for knowing where to hit with hammer £99, total £100.

[JTL]

If I could bill myself I would be a wealthy man. Next step in the process of getting access to the gearbox itself is for me to remove the inner cover. All screws and bolts have come off except for one hex bolt to the left of both shafts. Maybe some Loctite has been used or it's not supposed to come of. It's right threaded and hard to turn. What is it screwed into? Does it hold something on the back of the cover? Has it to be removed before I can remove the inner cover? In other words: what is going on with that hex bolt?... regards Jacob

[papasmurf]

You don't state which bike could the information you need be in one of the parts diagrams listed here:-
http://www.hitchcocksmotorcycles.com/parts-books-online

[PeteF]

No, leave that one. There should be 5 screws. One's hiding in the middle almost behind the selector.
You have removed the mainshaft nut? LHT mind.

[JTL]

Sorry, forgot to mention it's a 4 speed Albion gearbox on a 2003 Bullet (RH shift). The leave one hex bolt was left on, and the inner cover is now off. After being able to look at both sides of the inner cover and compare with the sketch in the parts book I have figured out what the hex bolt does. The parts book drawings are almost useless because they are so imprecise and lack of details. This is the reason for all the questions on this my first gearbox dismantle. Next challenge is to get rid of all the black goo in the box and to remove the layshaft bush in the foot starter spindle. It's worn and stock.