AJS/Matchless Lightweight Gearbox Overhaul

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Inspect the gears (2)

The output 4th gear ("sleeve gear") can suffer from wear. Check the exposed bearing track carefully and the inner bushes. If the inner bushes are worn, they can be replaced, but if the bearing track is worn or pitted, then the gear is scrap.
The other gears should be in usable condition (unless the gearbox has been run with wet oil). Check the case hardening for pitting and the bushes for wear.
There are three different types of 3rd mainshaft/2nd layshaft gear. They are generally interchangeable, but if you have the later output gear then you should use 044076 on the mainshaft.
There are two types of mainshaft 3rd/4th gear: the earlier dog/recess type (041276/041273) and the later undercut dog type (044076/044075). The earlier type is prone to jumping out of 4th gear. The later type solves this problem, but is often mixed up with the earlier 3rd gear. Try to pair the correct gears if possible.
The scrambler CS models have a higher ratio first gear - overall gearing on these models is is much lower due to the large rear sprocket.
The 1965/66 CSRs have a close ratio gearbox. This is apparently achieved by means of a 19 tooth 4th layshaft gear (043666) which replaces the 18 tooth one used on the other models. If you have a photo of one of these rare beasts, please send it to me!

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