“WSA SERVICE SHEET No. 31! Reprinted Pel, 1959 A and B Group Models with Swinging Arm Frame DISMANTLING AND RE-ASSEMBLY OF GEARBOX AND GEARCHANGE Gearbox Removal An inost cases if will be found couve nit to distantly the gearbox while it is still in position. Howover, if attention to the final drive piniun sleeve bearing is required it may be advisable (remove he complete yearhos, The primary transmission, clutch and chainease must be removed in either case and this should be carricd ont as described in Service Sheet $10, To remove the gearbox fren the frame, slacken the retaining bolls aud remeve the two tight hand rear engine plates, The gearbox is then (ree te be withdrawn from the right hand side of (he inachine. Dismantling Remove the clutch and speedometer cables. Move the yews (o Ute neutral position between first and second. Unde the four nuts and three screws round the rim af (he aaiter cover bud de aot slacken the serew and nut which are not on te crige of the caver as these do not prevent its removal. The outer cover eat then be removed complete with the kickstarler, gearchange and cluteli lever, As the cover is witdrawn the kickstarter lever will tend to rotate under the action af the return spring and the cluteh Tever should be pulled oul to the fullest extent so that the Kiekstarter lever nay be rested against it, thus preventing the complete release of the spriny The gearchange mechanism ean be disinautled by removing the gearchange lever aun the circlip whieh rete the gearchange spindle in the outer cover. Withdraw the spindle complete with change mechanisin which cut den he completely dismmuttled ater removing the split pin, sxamine the operating claw ‘4° for wear and if the ends are no longer well formed the claw should be replaced. Before the imer cover is removed the cluteh push rod should be withdrawn and the single screw to the left of the top right. stnd, musi be undone. The inner cover tagether with the mainshaft and gearchange rocking lever ‘B' can then be withtliuyn, leaving the gear cluster in position. “To remove the rocking lever the gear lever spindle bush nuust first fe pushed out of the inner cover, This will reveal tho end of the rocking lever spindle which is threaded internally J in. C..1. Screw in a suitable serew or bolt, then use this to pull out the spindle, Tit is necessary to remove (he maiushalt from the inner cover the shaft should be held in a seft jawed vice so that the kickstart rateliet nut ean be undone aéier ils loeking washer has been beat back. The kickstart ratchet, ratchet pinion, spring and bosh shouldB.S.A. Service Sheet No. 311 (cantd.) then be removed, leaving Ute shaft free to be pushed from its be be removed by prilling out the retai ng. This bearing eur ning civelip and then warming the cover in hot water ibhe soft rift. before tapping the bearing from ils housing with a st The rod “D! on which the two gear operating claws slide is pressed into the gearhox shell at the chitel cud and is secured by a small grub serew on the outside of the case, Release the grub serow and pull out the vod, TU is then possible io withdraw the gear cluster and operating chuvs together with the layshalt so that dhe only components ven ning in the gearbox shell are the final drive pition sleeve assembly ancl eam plate 'C Unserew the selector pliuger housing lacknut and remove the plunger housing fren: the gearbox shell. ‘The gear selector cam phate will now siide (vont its pivot and the butter car als be removed alter unscrewing the retaining nut and warming the shaft lesrings are a press fit in the gearbos aud if me aid of a soft punch. ary can be driven ont will th Kun a length of old cham round the gearbox sprocket and hold the chain ina view fo prevent the sprocket rotating. Flatten the locking tab washor and undo the revuining nut. Withdraw the sprocket from its spline, then tap ihe pinion into the gearbox with a soft amulet, ‘Ce raueve tie pinion sleey ring, prise ont the retaining cirelip, withdraw the oil seal, then warm the case in het water before lappeng tle bearing oul of the case, Deo nol disturb thy ballracy yaless if is suspected of being faulty. Wash it thoroughly in petrol te remove all traces of off and any play will (hen be ininediately detected, amine the varions parts for wear, and if the forks which actuate (he sliding pinioms show sigus of seizure it will he advisable to replace them. Attempts to erase the seizure mrarks will result iy oxcessive side play.B.S.A. Service Sheet No. 311 (contd.) The fixed pinions on Uhe layshaft and ovainshaft are pressed on, and new components must be a tight fit sary. The rocking arm shoul] be replaced if the teeth show signs of wear as, of , should pinians with damaged or worn teeth, amine the selector plate for worn cam grooves, and replace if nueus cours Re-assembly Re-assembly is carried out in the reverse order to dismantling, ‘The aluminium case should always be warmed before a bearing is pressed in. When replacing the gearbox sprocket ensure that the oil seal is in good condition and that the retaining nat locking washer is correctly seated in the spline. Tighten the nut fully and turn the lockwasher ove new sprocket must be fitted otherwise rapid chain wear will result, nto the slots on the mut. Lf the teeth en the sprocket are worn to a hook shape a Replace the cam plate and selector plunger making sure that the phinger is in the neutral position between first and second gear. Place the layshalt in position and theo feed in the first puur of years ‘J" and ‘7 together with their selector claw ‘22 These claws interchangeable but if the original components are to be uscd then they should be replaced in their original positions, Replace thy: xecond pair of gear wheels ‘6 and ‘#? together with seluctor claw ‘dc’ and make sure that the guide pins of both selector claws are correctly engaged in the cum groove, Replace the selector elaw rod and secure it in position by incans of its grub screw. Position the spacing washer and the large pinion on the layshaft. Assemble the mainshaft, kickstart ratchet mechanism: and recking lever into the inner cover. ‘The mainshaft and inner cover can then be pushed into the gearbox, but before they are completely home the rocking lever must be correctly st so that the red dots on the lever and on the cover are in line. Replace the single inner cover retaining are screw, Note that when a. reverse cam plate 42 3001 is fitted the red dots will not coincide deseribed above. Correct meshing of the rocking lever mest be obtained by trial and error, Assemble the gearchange and kickstarter mechanisin in (he outer cover, them push the latter on (o the four studs, rotating the kickstarter slightly so that the qnadrant does not jam on its stop. Replace the four nuts and three serews in the outer cover, The gearbox is now completely re~assembled. BSA. MOTOR CYCLES LID, erviee Dept., Birmingham, 10, Printed in England