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AJS/Matchless Lightweight Gearbox Overhaul

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AJS/Matchless Lightweight Gearbox Overhaul, Inspect the main casing: crwdns2935265:00crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 AJS/Matchless Lightweight Gearbox Overhaul, Inspect the main casing: crwdns2935265:00crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 AJS/Matchless Lightweight Gearbox Overhaul, Inspect the main casing: crwdns2935265:00crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
Inspect the main casing
  • There are many ways in which the Lightweight gearbox can wear. Don't worry if the components aren't perfect; these gearboxes are simply designed and will usually continue to function well, even when worn.

  • In the picture, a breather union (visible in the top-right corner) has been fitted to the gearbox casing . This is a modification for racing use, so it can be ignored here.

  • The layshaft bush is almost always worn oval. It may be so loose that it just falls out; assume you will need to replace this bush.

  • Check the large output bearing for signs of corrosion or roughness. If in doubt, it is a good idea to replace it. Note that it is a special part and is very expensive.

  • Check the output seal for signs of oil leakage.

  • Check the selector pivot shaft is secure. It can work loose and cause oil to leak from the end of the casing.

  • Check the two steel plugs are secure and oil tight. Drift them out if in any doubt.

  • Later gearboxes may have a hole for a pin to secure the layshaft bush. Check the pin for security or signs of oil leakage. Remove it if in doubt.

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