Shimming

Shimming

1. Fit new bearing tracks to front cover.

CAUTION: Ensure input shaft bearing & track is correct for type of front cover fitted. Early covers having a lug each side of cover, bearing track is retained with a spring clip. Later covers having a lug on one side of cover, press bearing track into cover using a suitable mandrel.

2. Fit front cover to gearcase without oil seal.
3. Clamp gearcase in vice with front cover downwards.
4. Fit input shaft.

CAUTION: Do not fit 4th gear baulk ring.

5. Fit output shaft assembly to input shaft.
6. Fit output shaft bearing shim and track to centre plate.







7. Fit centre plate and bolt down using 8 off 8 x 35 mm slave bolts.

CAUTION: Do not fit detent ball or spring at this stage.

8. Fit large ball bearing to rear of output shaft.
9. Mount dial test indicator.
10. Rotate output shaft to settle bearings.
11. Lift output shaft and note DTI reading.
The end float setting for the output shaft and layshaft is:-
Early gearboxes without suffix K added to serial number:
New: 0.01 - 0.06 mm (0.0004 - 0.0024 in)
Service limit: 0.06 mm (0.0024 in)

Later gearboxes with suffix K added to serial number:
New: 0.00 - 0.05 mm (0.00 - 0.002 in)
Service limit: 0.05 mm (0.002 in)

Shims to make up the required clearances are placed under the respective bearing tracks in the centre plate.

12. Dismantle and substitute shims if reading incorrect.
13. Remove output shaft assembly and repeat procedure for layshaft.
14. Remove centre plate, layshaft and output shaft.
15. Remove front cover.
16. Remove input shaft bearing track from front cover, retain track with cover.