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AJS/Matchless Lightweight Gearbox Overhaul

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Remove all traces of gasket or sealant from the centre web.

Check the kickstart mechanism and bushes for wear and damage, replacing as required.

Fit the kickstart return spring using a pair of long-nosed pliers, noting the washer underneath the spring (if fitted). Use a pair of pliers to make sure the spring is fully engaged in the hole in the shaft.

Don't forget to fit the coil spring on the gearbox side.

Temporarily fit the kickstart and rotate the shaft by hand more than 90 degrees to tension the return spring.

Fit the kickstart pawl, then release the kickstart so that the return spring is left tensioned by approx. 90º. It takes a few goes to get it right.

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