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[martyn15]

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[Tim NZ]

In service the mainshaft is located inside the end cover bearing, ie to the right.


You may simply be in a situation where the shaft (and its gears) and all sitting too far to the left?


If you have had the High gear pinnion dog off, make 100% certain that it has gone back onto the shaft the right way around, or you will be able to engage 3rd and 4th gears simultaneously!


Death!

[martyn15]

thanks Tim - the shaft is torqued up at the clutch end with no thread protruding past the nut itself, so I think the shaft itself is OK. i was wondering if the small high gear pinion has been pushed too far onto the shaft? is this possible? the dog engages correctly and all the other gears in the box line up fine. cheers

[Tim NZ]

I am not sure I understand how you are assembling the gear box???


The sleeve gear is retained by the gearbox sprocket and nut. Is that the nut you are referring too?


If you insert the mainshaft and all is associated gears into place in the casing, the mainshaft will be positioned too far in, and you will have issues with not being able to rotate the gear cluster.


The fitting of the oil slingers either side of the inner cover bearing are pulled up onto both sides of the bearing when you tighten the LH thread nut at the end, effectively drawing the main shaft back out of the gearbox to align all gears.




If you dummy preassemble both shafts and gear sets onto the inner cover (which is from where the gears and shaft are aligned and spaced out from) you will then be able to see if you have any gear alignment issues.


Dont loose the layshaft thrust washer inside the end of the Kstart!!!

[martyn15]

thanks Tim I was referring to the nut on the inner shaft that holds the clutch on. Ill try the dummy assembly as you suggest

[martyn15]

it all lines up now- thanks