Gearbox Surgery

[BrettS]

I keep forgetting about that Jeff.

A little update on the gearbox issue side stepped by swapping motors.
Had a chat with Mal and he is thinking the noisey 1st and 3rd gears in the police motor are probably 1 or more bad bearings. Not sure if that answers the strange backlash/ knock in 5th.
Might have to retire that motor for good

[excess.11]

Love the meme Bretsky...well done on your perserverance...i can feel an award coming on for that achievement.
PS.....mr slack ass empty head (me)...will deposit ....you know what..into..you know where...this weekend.

[BrettS]

Maybe your just not as good a puller as me!

[Jonesy :-)]

Brett,
 the moving shaft must have a circlip missing, otherwise there is no way it can move

[excess.11]

"Vernias" I hate the ipad

As much as spelling ?
Verniers ?
But hey...what i want to know is...what up with the holed pistons in the sidecar outfit...are we talking about the one at this years meet up...or another in your horde.
How..what ...when...?

[BrettS]

Success, all gears are sound and it all works pretty smooth. I don’t think that’s any clarification on shafts moving or not. I will follow that up pulling on every shaft I can find and encouraging others to do the same. I’ll also keep pulling the police motor apart and see if I can find a reason for the issues it was having. I think all the parts I have moved over to the replacement motor could be struck of the list. Lower gear set including shifting forks, Clutch basket, Cush drive , shifter assembly and the rest of the bikes driveline. There is not a lot left over in the motor, glad I was forced to swap motors and didn’t have to chase this issue. The bike is running pretty sweet all round, pods and all it pulls strong n smooth. Finally have a bike that I can say nothing is wrong with. Well maybe a couple of little things to cross of the list but damn it’s close.
Only took me 6 or seven years lol

[XSIIE]

"Vernias" I hate the ipad

[XSIIE]

You might need to get the vervains out and check washer/shim/cog thicknesses

[BrettS]

Thanks Eddy, Andy checked his spare motor and could not find any movement. I think Jonesy’s and Andy’s are both RH motors. It’s a long shot but as the other gear set is slightly different maybe this could be.
It just seems too strange to have two motors with a loose shaft and wrong, not out of the question but still strange.

[XSIIE]

Brett, i need to do some motor surgery on the sidecar (holes in pistons) can check the shaft this weekend.

[BrettS]

Pulled the motor in the bike apart today and swapped the full lower set of gears and selector forks into it from the police motor. Did it standing upright, getting the gears and selectors back in was a real pain in the arse but it is very doable, especially with a system. Still got the sundries to get back on tomorrow to test.
I found the main axle ( clutch shaft) moved the same as the police motor did.
I got Jonesy to pull on his shaft again and he is adamant that his does not move. Wondering if anyone has a bare shaft out there can they give it a pull for me. As considering both mine move I’m not convinced it should not move. I found sometimes you need to play with it a bit to get it to move.
Thanks 

[BrettS]

Yes some times I just need someone to show me how smart I am
Or is that to remind me to look at everything, I’m confused again :/

[steptoe]

love collaberation, problem solving at it's best

[BrettS]

Collaborating with Jonesy on the phone today I think we found the problem with the police motor gearbox.
Main axle (clutch shaft) has some back n forth play that should not be there.
My guess is the shim next to the main circlip holding the axle in place is missing. I will have to split the case to find out.

[BrettS]

Got the exploded diagram and without taking apart but inspecting carefully I can see everything is in the right spot except it has had the 2nd gear washer swap. Probably why 2nd works so well.
I had previously checked the outside bolt washer spacer setup that is different from standard to special and I believe I have that correct. Mine had a dodgy washer bolt setup and I replaced with correct Genuine bolt.