I bought this box off a French guy at Kempton about 5 years ago for £100. It had two layers of army green paint heavily glooped over a layer of black paint, which I've stripped off.

It clicked nicely through all gears in the vice and since taking it apart, the gears all look like new. The mainshaft is an even .001" down from 7/8" through the sleeve gear and there is a little bit of slop! So when Les opens up for business again on the 30th? I'll order a new sleeve gear bush/bushes and ream it to size. Les has the original gaskets too, not the thick ones that are on sale elsewhere. I've also got a sealed FAG bearing coming from Darren W.

The pivot pin for the clutch lever was a bit worn, so I cut a new one from a piece of 1/4" silver steel.

It's just a spare gearbox in case either of mine go wrong......Hopefully I'll never need it:relaxed: Ron

email (option): ronpier@talk21.com

Hi Ron you might want to make one of these tools I knocked up for fitting the kickstart quadrant ?..Make fitting or removing a lot easier.....Dave

Good tip Dave, but I've already dealt with that and fitted a new bump stop rubber:relaxed: Ron

email (option): ronpier@talk21.com

It must be the Corona 'catchup' virus...I've just rebuilt a BSA box for a late A10 RGS that I 'found' when I was looking for something else in the workshop loft...I can't even remember buying it so it's been there a while!....Ian

email (option): ian@wright52.plus.com

My mate John made me a new bronze sleeve gear bush. The one I pressed out was brass? I heated the case and fitted Darren's sealed bearing, fitted two new gear change springs and proceeded with assembly this far. It clicks through the gears.... As well as an M20 box can in a vice!!

Kick-start cover and final clean up next. Ron

email (option): ronpier@talk21.com

Ron,

Any tips for how to best fit that spring hook on the quadrant ?

I tied coat hanger at the loop but now need to secure cover on the milling table.

Looking at the suggested tool but not clear if that is meant for that.

Thank you for your comments

Dave's suggested tool should help Henri. Ron

email (option): ronpier@talk21.com

Thank you Ron,

If the rubber piece wasn’t there maybe.

Just the same, the coat hanger did it.

Tool can be used with rubber stop in place, First roughly place quadrant into outer case & hook the spring onto quadrant, then insert tool and turn until it hits the stop(2nd photo) then turn tool clockwise until you clear the stop rubber in outer case then just push quadrant into outer case. 1st photo shows how to use tool to remove quadrant, same thing insert tool till it catches the return spring the turn clockwise and wiggle out quadrant once clear of stop on outer casing.I made this tool as I got fed up with fiddling around trying to get return spring into place this tool makes it so easy and is worth the 1/2 hour of time to make....

Thank you Dave for the clear explanation and congrats on coming up with an easier solution.

No skills in my CV for welding nor silver soldering. But I will keep your photos in my to do files.