Workshop Manual
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Hughie Hancox
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Haynes
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Mainshaft and layshaft bearings Inner gearbox cover
(Mainshaft ball journal bearing S35-7 - 3/4 x 1 7/8 x 9/16")
- Heat inner cover to 100C.
- Press or drift in mainshaft bearing.
WS Man says use 2 1/2" drift, but that would be for the high gear bearing.
The mainshaft ball journal bearing is 1 7/8, not 2 1/2.
- Install circlip.
- Open end needle roller bearing
(57-1614/TIMKEN B1112 - 1 1/6 x 7/8 x 3/4")
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Mainshaft and layshaft bearings Inner gearbox cover
(Mainshaft ball journal bearing S35-7 - 3/4 x 1 7/8 x 9/16")
- Cool the mainshaft (S35-7) and layshaft (57-1614) bearings.
- Thoroughly heat inner gearbox cover.
- Fit the mainshaft bearing (S35-7) (Tool-Z15)
- Fit the open end needle roller bearing (57-1614): using a
soft-faced mallet and the
(high gear end) of layshaft as a drift, drive the bearing in
from the inside of the cover, leaving it protruded just
below the depth of the thickness of the thrust washer (57-1607).
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High gear ball journal bearing
(57-0448 - 1 1/4 x 2 1/2 x 5/8")
- (Old bearing driven out from inside gearbox using a
shouldered drift (Z15) on inside race).
- Drift in new bearing with (<)2 1/2" drift on the outer race.
- Put in new circlip.
- Press in new oil seal.
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High gear ball journal bearing
(57-0448 - 1 1/4 x 2 1/2 x 5/8")
- High gear roller bearing
- (with the right-hand half of the crankcase
lying on its side on the workbench...)
- Thoroughly heat the area around the bearing housing.
- The bearing should then 'drop straight in' (as it does
in the video)
- Fit the circlip.
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Layshaft closed-end needle roller bearing
(57-1606/TIMKEN M11121 - 1 1/6" x 7/8" x 3/4"
- Heat casing to 100C. (Cool needle bearing).
- From inside the gearbox, use drift with shoulder profiled to give
proper bearing protrusion for the thrust washer.
- Seal the outer portion of the bore into which the bearing seats.
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Layshaft closed-end needle roller bearing
- Put crankcase in a vice (more or less normal orientation)
- Use the layshaft with a soft-faced mallet as a drift
to 'gently tap it home' (I count a dozen medium blows with the
soft-faced mallet).
- Insure that the bearing lip is below the face of
the bronze thrust washer.
- High gear bearing oil seal, open side to the
bearing - tap it all around (like 25-30 times) with
a ball peen hammer (beat the sucker in!).
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High gear and drive sprocket
- Drive a new oil seal up to the main bearing with
lip and spring facing the bearing.
- Press the high gear into the bearing.
- "...ensure the oil seal is correctly engaged over the protruding
nose of the high gear". (D15, WS-M).
- Lubricate and tapered boss of the sprocket and slide it into
the high gear.
- Apply sealant to the splines.
- Put the sprocket nut and tab washer on finger tight.
- Install drive chain and use rear brake to hold the sprocket
so you can "tighten the sprocket securing nut as tight as possible"
(Tool Z63).
- Tab over the lock washer.
- Oil "the extended high gear with oil" and replace the door with a new paper gasket.
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High gear and drive sprocket
- From the inside of the gearbox, insert high gear
through the bearing and oil seal.
- Push on sprocket with drop of oil where the flange
runs in the oil seal.
- Place the case over an open vice, sprocket down, and
use a 'suitable drift' (think big) to drive the
sprocket all the way onto the high gear.
- Fit tab washer and large sprocket nut.
- Tighten the nut
Note: Neither shown nor quite clear to me how he does this
as the case is not in the frame and therefore
can't be held by the chain and rear brake.
- Replace and tighten camplate plunger holder.
- Replace and tighten gearbox drain bolt.
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High gear and drive sprocket
- (Mainshaft main bearing & circlip installed)
- Install (57-0946) high gear bearing oil seal w spring to gearbox.
- Lubricate and "drive" the mainshaft high gear (57-2316 26T)
through the oil
seal from inside the gearbox without damaging the seal lip.
- Lubricate and insert the final drive
sprocket (57-1918, 19T), tapered end first, over the sleeve
of the high gear.
- Install new tab washer and hand-tighten the large BS 1 1/4"
nut (57-0440).
- Connect the final drive chain.
- Apply brake to tighten the nut (50lbs torque, WS-M).
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Install mainshaft into inner cover HH
- Hold mainshaft "firmly" vertical by the splines in a soft-jawed vise.
- Place the inner cover over the mainshaft being held in the vise.
- Install kickstarter assy: washer, sleeve, spring, pinion, top rachet, tab washer, and nut.
- Tighten nut and fix with tab washer (check to insure kickstart ratchet turns freely).
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Camplate and gear cluster WSM
- Install camplate plunger, spring, and holder.
- Lubricate camplate spindle and introduce into gearbox with the camplate
plunger engaging in the notch between 2nd and 3rd gears.
(Figure D12, not Fig. D14 as specified in the WS-Man).
- Install the left thrust washer w grease - grooves towards layshaft.
- Lubricate all moving parts in the gear cluster.
- Assemble the entire gear cluster, including shifter forks and
rollers, and introduce into the gearbox.
- While sliding the two shafts into their left-hand bearings,
move the gears in and out to position the rollers into the
camplate groove.
- Lubricate and slide in the shifter fork spindle and seat it in the case.
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Camplate and gear cluster HH
- Use grease to hold in place the inside thrust washer (grooves towards gear cluster).
- Fit camplate spring and plunger with a spot of oil.
- Lubricate the camplate shaft, depress the camplate plunger with screwdriver, and fit the camplate in the
1st gear position.
- Lubricate layshaft and fit layshaft 2nd and 3rd gears.
- Insert layshaft complete with 2nd and 3rd gears into the gearbox and into the closed-end needle roller bearing.
- Place roller with grease on layshaft gear selector fork.
- Fit the layshaft gear selector fork to 2nd and 3rd gears, locating
the roller in the camplate.
- Lay the mainshaft gear selector fork behind the layshaft gear
selector fork and locate the roller in the camplate.
- Insert the selector fork rod through both forks and all the
way home into the gearbox case.
- "Fiddle" the mainshaft 2nd gear in and engage the selector fork.
- "Fiddle" the mainshaft 3rd gear in and engage it with selector fork.
- Fit layshaft low gear.
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Gear Cluster Hayes
- Lubricate camplate spindle and install camplate in gearbox.
- Position camplate so that camplate plunger will engage the
camplate BETWEEN 2nd and 3rd gear notches.
- Install camplate plunger, spring, fibre washer, and nut.
- Check and maintain camplate position.
- Install brass thrust washer over protruding (closed end) layshaft
needle bearing with grooves facing into the gearbox. Hold in
place with grease.
- Assemble the gear cluster complete with fork selectors and rollers
and install into gearbox as a unit.
- Lubricate and insert the selector fork spindle through both
fork selectors and all the way home into the casing.
- Using grease, install 2nd thrust washer over needle roller bearing in inner cover.
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Inner cover WSM
- Install the right-hand thrust washer with grease - grooves facing in
towards the left-hand thrust washer.
- Apply joint compound.
- Push on the inner cover, stopping 1/4" away to "position the camplate quadrant in
to the middle point of its travel and push the cover fully home".
- Installed this way, "the middle tooth of the quadrant should
align with the mainshaft center line".
- Check shifting.
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Inner cover Hancox
- Fit inner cover thrust washer with a dab of grease.
- Coat inner cover and gearbox faces with joint sealer
- Lubricate the mainshaft, which is fixed in the inner cover.
- Fit inner cover with mainshaft to the gearbox.
- Hancox taps cover on with quadrant on gearbox floor until it touches.
- Then, taps back the cover slightly to free the quadrant,
and dips the quadrant (rotates it clockwise) ever so slightly until
it just engages the camplate.
- Finally, tap the cover home.
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Inner cover Hayes
- Apply joint compound to casing and inner cover.
- Confirm camplate plunger is between 2nd and 3rd gear camplate notches.
- Slide casing on while correctly positioning camplate quadrant with the camplate.
- Install two screws and bolt holding on the inner cover.
- Reconnect oil pipe junction with new gasket.
- Temporarily install outer cover, check for proper gear operation.
- Remove outer cover.
- Install the kickstarter assy (washer, spring, sleeve, pinion, ratchet).
- Install a new tab washer (57-2240) and the 21-0594 retaining nut.
- Using brake to hold the mainshaft, torque the nut to 45lb, but don't over tighten otherwise it may distort
or break the kickstarter pinion spacer.
- Replace clutch rod.
- Replace right-hand engine mounting plate.
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Outer cover WSM
- Install kickstarter washer, spring, pinion, ratchet, and washer. Then put on nut with blue Loctite
and torque to 45lbs with brake locked and engine in 4th gear.
- Refit outer cover.
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Outer cover Hayes
- Apply joint compound to inner/outer cover matching surfaces.
- Pre-tention the kickstarter and slide on outer cover.
- Replace outer cover screws and bolts.
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Finish up Hayes
- Install a new oil seal (70-7565) in the chaincase inner cover plate
(open lip/springs face primary chain case).
- Fit a new joint washer (70-3832).
- Install inner cover plate being careful not to damage oil seal lip.
- Fasten inner cover plate with 6 counter-sunk screws (70-3821).
- Install transmission.
- Replace foot rest, exhaust pipe and muffler.
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