To Strip the Bearing Carrier
1. Wash, clean and inspect the hubs, dog rings, gears and gear bearings for signs of wear and cracks. Pay particular attention to the wear on the dog teeth of the gears and the dog rings. Replace all parts as necessary.
2. Examine the forks for wear and test for excessive play between the forks and dog rings. Replace any worn forks.
3. To remove the forks, undo the nuts and slide the forks from the selector rods. Take care not to lose the fork shims and always keep the fork with its relative shims.
4. Remove the three grub screws and take out the top selection rod springs and balls. Then remove the selector rods one at a time followed by the bottom balls and springs.
5. Undo the small grub screw and take out the interlocks.
6. Inpsect the layshaft and pinion rear bearings and replace as necessary. The bearing retaining screws need to be taken out and the bearing carrier heated to release the bearings.
7. Examine and crack test all parts carefully. Any components showing cracks or excessive wear should be replaced.
8. Reassemble in the reverse order paying particular attention to the following points.
- When replacing the bottom springs and balls that control the tension of the neutral position, the balls must be at the correct height. Approximately 1/3 of the ball should be exposed in the selection rod bore.