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[Sticksy]

I wondered if the 15t gears in a 1961 500 Bullet gearbox have been mixed up?
The gear at the end of the mainshaft-HG9/15- has the teeth on one side quite obviously bevelled,on the inward side.
Should it be fitted to the layshaft instead?
The reason i ask is that after fitting new bearings - fully seated in the casing, the outer edge of the teeth on the layshaft gear-Hg17/15- are hitting the edge of the ball main bearing.Is the gear bevelled to avoid this, i wondered?

The problem with swapping the two gears is that the bevelled one is 0.030" longer, which removes layshaft end float, so would need 0.030 facing off one end.

Seems quite a laborious way of putting things right, so if anyone has any ideas i would be very grateful.
Thank you.

[scotty]

Have a look in tech notes rebuilding 4spd box something about similar gears but only one can be fitted inthe correct position. Worth a look or download and print, think its in 4 sections.

[ric]

Could those bevelled teeth be the ones that engage with the kick starter pawl ?

[Tim NZ]

In the Indian gear box (effectively the same parts) the two gears are one and the same, but the Indian gbox uses a inner case gasket, which effects lay-shaft end float...


First, you need to make 100% doubly certain that the 6206 brg IS fully seated..?


The gear must be fully pressed onto the shaft, and the bearing fully seated in the case. Or no matter what, either gear is be able to rub against the outer race of the 6206.


Check that the end flange of the lay-shaft bush is not damaged...

[Tim NZ]

Foot note: With the Albion made box, the 'Stepped' gear is fitted to the Lay-shaft, with the 'Step' inwards.


Should have mentioned that detail earlier...

[Sticksy]

Thank you everyone, especially Tim.
I bit the Bullet,Hmm,and removed the oil seal to check the main bearing and it had moved inwards - Oops! My fault. All seems ok now but the shafts seem to have a lot of end float compared to other gearboxes eg, Norton.
Thank you all for your kind advice. Lesson learned!