Thread: Operation Ralph!

who said to look out for the layshaft rear bearing?
'coulda said it a bit louder, --- yep, I buggered it.


this gearbox is so good, even still has the grease on the bearings from assembly.

It was a team buggering effort!!!!
Oh well at least i am getting a lesson on how a series gearbox comes apart and goes back together. At least we found[ATTImageUploadedByAULRO1408777662.385336.jpg a couple of problems in the old box.ACH]82581[/ATTACH]

Hi Ian,

That bearing is a bugger. Looks like the bearing you had in there is the cheaper type. I just rebuilt a series 3 box and had real trouble with the layshaft bearing that came with the kit I got. I ended up having to buy another bearing and it was not cheap to get a good one. CBC got an RP (English) bearing for me and it cost $100. The difference in quality and ease of fitment was very obvious. I could not even get the layshaft in because the rollers in the bearing kept tilting and even falling out. Put the RP bearing in and the shaft fitted first time.

Cheers,

Tim.

One thing that can make the layshaft a little easier to get in place is to use a bit of string to hold the reverse idler gear forwards while you manoeuvre it in. Then just pull one end of the string and it comes out. In the series 3 the layshaft should be in place before you try to put on the bell housing and it a real juggling act to hold the constant gear in place while you put it all together but I am not sure that the Series 2 is the same from the manual I have.

Cheers,

Tim.

Thanks for the info Tim, i"ll go shopping on Monday and track one down. Steph just said its time to crack a bottle of red and who am I to argue with that!.decisions decisions. ImageUploadedByAULRO1408780534.174513.jpg
Have a good night,
Regards Ian

Well I got the lay-shaft tail bearing, (RTC1412) and a new gasket kit for the box. I just dropped off the main box housing to an old engineering friend who is removing the bearing shell from the box and fitting the new bearing to the
lay-shaft for me. Hopefully we can get the box back together and refitted with the engine this Saturday and Sunday which is Fathers Day, I get to do what I want . I have to replace the clutch on the bike tonite as we are off for 10 days, riding to Canberra the following weekend for the Floriade Festival and wedding anniversary, we found a route down and back that doesn't touch either the Pacific or New England Hwy's which will be a lot more relaxing, and we have a club trip to Border Ranges National Park 2 weeks after that and I want to swag it in Ralph.
Regards Ian

Got the new gearbox back together with Harry and scanfor's help, thx guys. Put it back in place this morning, fitted up the rear prop shaft but the front one is about 1/2" too short to mate up to the transfer case. There was no markings on the new parabolic springs to show front or back but i was wondering if they could of been fitted back to front. Has anyone else come across this?
Cheers Ian

get a tape measure and measure the wheelbase.