July 27, 2019
Attempting (heavy emphasis here) to rebuild a D5 and having an issues with gearbox. On assembly of gear cluster all works ok with selections and neutral but when left hand casing tightened up neutral disappears. It is still there until the last bit of tightening and on further investigation it seems that the 32T layshaft pinion is the cause as I can simulate the problem by apply a small amount of pressure on the pinion when the cases are still split. I’ve checked that there’s nothing missing from the cluster. I’ve replaced all bearings and bushes and there doesn’t seem to be any tightness but on reading other posts am now concerned about the bush alignment.
Any thoughts from people who have a lot more knowledge than this beginner would be appreciated
June 23, 2013
January 9, 2013
the only thing i have is moor for uthers me being absolotly «censored» at speling i memarise most stuff coz it sounds funny but just have tryble reading wot iv rote down its like this my note book gone walkabout it was full of sizes & drewing of like how deep a bush & bearings in situe & if its a crackshaft il say or gears do a dummy asembly run with said bits so in this situ put all gear parts in the cases NO c/shaft or hermatyt & see if it works sort any probs time & time again ,. so that s how i do it chaps id like to say thank you to all you guys that can understand my input grate stuff thanks Sunny
December 26, 2019
November 16, 2011
July 27, 2019
Hi again. Something of a hiatus in my attempts borne out of frustration but also other events. However thanks to the advice from Sunny I started again and by a process of eliminating the pinions one by one determined it was actually the right side mainshaft bearing wasn’t seated far enough in so there just wasn’t the right space available. That’s sorted now and have now done a “dry” assembly of engine which has revealed the need for several replacement or indeed missing parts.
Thanks again for the advice; will probably be back for more before too long 😀
April 19, 2018
Hi Eamon. Glad to hear that your making some progress. To the put your mind at ease and while you've got the cases apart, it might be worth sourcing a set of earlier gearbox shafts which are generally considered to be more reliable. There's loads of threads on the topic. Have a look ** Please log in to view ** for previous discussion.
'55 D3 Battery; '58 Square Four (project); '59 D1 direct lighting plunger; '59 Tiger Cub; '60 5TA; '76 FS1-E; '91 GTR 1000; '97 Honda Sky SGX50.
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