March 8, 2009
While cylinders are at the machine shop, I set to work on the gearbox. I normally replace all bearings and bushings in a transmission while it's open, whether they appear to need it or not.
[Click pictures for a better view]
Shown here are most of the parts of the gearbox:
This is a drift made especially to press in the layshaft needle bearing in the left side of the case. The bearing needs to sit about 0.075" proud of the case. The recess in the drift accomplished this.
New mainshaft and layshaft bearings in the left side of the case, and new main oil seal:
The other end of the layshaft runs in a needle bearing in the kickstart spindle. This bearing is in a blind hole, and was a real pain to get out. Shown is a drift to help install the new bearing.
New mainshaft bearing in the inner gearbox cover:
New bushings for the mainshaft high gear and the layshaft low gear:
The kickstarter stop plate is what stops the kickstarter when it returns to rest position after a kickstart. The stop plate and the boss on the kickstart spindle that hits it had both deformed quite a bit. I replaced the plate and reshaped the boss on the spindle to have better contact.
New bushes and bearings.
Ready to go together.
Main and layshafts assembled to the inner cover, and the gear selector mechanisms added:
Main case ready to accept gearbox subassembly, and the gearbox installed.
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