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The rebirth of Lazarus
Oddjob:
Lots of pics coming up so may split the reply.
Gearchange shaft, the one I found today I gave up on. The end that goes in the clutch case was perfect, lovely condition, the shaft though was really rusty and I was concerned the it would bugger up the oil seal. That saying where the seal sat looked ok but the rest of the shaft has to pass through the seal before it gets fully into place. So whilst I haven't binned it I looked for the other one. That was the opposite, shaft really nice, bit of corrosion but nothing too bad. The other end though was rusty as hell. Took me a couple of hours to get it to look nice again. Checked everything and can find no faults. Splines for gear lever are great, tested with a lever I'm currently working on and it just slid on and even without a pinch bolt it wouldn't slip. The large spring is still soaking but is good, so I'll refit that as soon as I've cleaned it.
Next item. No 12 or 23491-286-030. Removed it from the shaft, really starting to hate those odd circlips, even with decent Snap On circlip pliers as soon as you expand the clip it twists round and won't come off. The gear wasn't too bad, fair amount of rust but surface type in general. Cleaned and inspected, cannot find any fault with it, all teeth good, no chips, dogs in good nick. Came out pretty good as well. Looks almost new.
Laverdaroo:
You're a top man Ken :)
Oddjob:
Next item. Here's where it starts to get complicated, sorry.
No 10 gear or 23471-286-010. I found 2 of those but gave up on 1 as it was a little too rusty and it wasn't worth the effort to clean it as I suspected it may fail after a few years of use. It was marginal and if the part was really really rare and unobtainable I'd have used it but it's not so in the bin it goes. The other wasn't anywhere near as bad to start with and after cleaning and inspecting I can find no faults. All gear teeth ok, no chips or signs of uneven wear, Both sets of dogs are good.
So those are the 3 items you want BUT as Bryan says gear No 10 usually comes supplied with gear No 5 as No 5 was changed after the K0. Here's the complicated bit. I found 2 No 5 gears 23420-323-010 or so I thought. One still had the bronze bush inside it, the other didn't. They look identical but on closer inspection and only because I'm a perfectionist did I spot this. After cleaning them both up I was wondering which to offer you, both came out great, no damage. However the one with the bronze bush still installed was bugging me as it wasn't fully driven home. Tried to move it, nope. Stuck hard. Got the old Mapp gas torch out and heated it up. Tried to tap it out, nope. So using the other one as a test sample I found a socket to drive the bush out, wasn't a great fit but it would do. Took it back to the vice and strangely the socket is now too big, odd. Another smaller socket found and more heat and out she popped, promptly rolled off across the garage and hid itself whilst gently steaming at the same time. Went to pick it up, forgot it was mad hot and burnt my fingers, suitable swear words later and back to the vice it goes. Only when this bush is removed does it become apparent the 2 gears are very slightly different. Out with my NOS gear complete with part label and it's clear the one I've just removed the bush from is not 23420-323-010 but 23420-323-000. So it's from a K0 engine, most likely the same engine as the cases are that your having. This is really odd as to my knowledge I have never broken a K0 and there weren't that many around to break anyway, yet I have 2 sets of engine cases both beginning with a 1 not a 2 like the K1. I did buy a few spare engines back in the day and acquired a few more when my family was also buying 500 engines for their bikes.
So here's what they look like. 000 first. You can see a small lip on the central boss.
010. No lip, smooth straight through hole.
The other bush is like a top hat on 010, I used the bush out of my NOS one to show the difference.
So to put this simply, you need to find out which of the 2 types you currently have. Does it have a top hat bush which comes out easily and is therefore a 010 or a pressed home bush like 000. It's the large gear next to the needle roller on the countershaft.
Oh 1 last thing, the little dots etc you can see on the gears are not rust spots or pits, they are just the way they are cast, it's not a smooth surface by any means.
mickwinf:
thanks for all your efforts Ken, i will have a look over weekend and see what i have
mickwinf:
Hi Ken i have just had a closer look at my gearbox and have found some more issues. Firstly the gears you have are perfect, numbers 10 and 12. My gear no 10 has the top hat style bush and seems in good nick. Bad news is the countershaft has some corrosion on the part that the oil seal rides on and not sure how well it will clean up. Also the c/s main bearing is noisy and rough, as are the two needle roller bearings on both shafts. Mainshaft seems ok all gears are sound as is the bearing. I agree with you about the circlips, awkward little beggars, will try to get new ones.
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