25 - Building Up Crankcases

 All the bits of the engine have been sitting around in a box since being cleaned so I spent a couple of hours today putting the crankcases together. Here's a step by step photo gallery of the gearbox rebuild. Sorry for the quality , they're only taken with my phone. Everything was in good enough condition.  The main shaft was repaired by Travan Engineering over 20 years ago. I think the guy might be dead now. It was hard chromed plated and ground then oil-lite bushes fitted in the sleeve gear. A good repair that has lasted well.

kickstart mechanism

output sleeve gear

hard chrome repair on mainshaft

selector drum installed

mainshaft gear train

layshaft gear train

first selector fork

second selector fork

third selector fork

note top side of layshaft gear

note top side of gear has raised edge

gear added to mainshaft

detent plunger installed

kickstart gear installed

note thrust washer on kickstart gear

new gasket

crankshaft installed