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AJS/Matchless Lightweight Gearbox Overhaul

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AJS/Matchless Lightweight Gearbox Overhaul, Fit the blanking plug and oil seal: crwdns2935265:00crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 AJS/Matchless Lightweight Gearbox Overhaul, Fit the blanking plug and oil seal: crwdns2935265:00crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 AJS/Matchless Lightweight Gearbox Overhaul, Fit the blanking plug and oil seal: crwdns2935265:00crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
Fit the blanking plug and oil seal
  • Tap the blanking plug home with a little Loctite 603 to hold it in place.

  • If your casing has a hole next to the layshaft bush, an M3x19mm screw appears to fit perfectly. Use some Loctite 603 to hold it in place.

  • Ensure the other end of the retaining screw is recessed at least 1mm from the layshaft bush surface.

  • Fit the metal spacer (larger diameter inwards) into the oil seal (metal side outwards) and tap the seal into the casing. When fully home, it should sit ~4mm in from the outer surface i.e. do not leave it flush, otherwise it will bind on the sprocket.

  • The output seal (041267) is the same as the one used on AMC Villiers 2-stroke gearboxes. Size is 1.81" x .131 x .21"

  • At this point, it is a good idea to test fit the sleeve gear and outer sprocket to check that everything turns smoothly.

  • If the sprocket binds against the seal, make sure the seal is fully home.

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