Urgent G2 gearbox shaft leak help for Newby

Information relating to the Matchless G2 or AJS Model 14 250cc Lightweight
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Urgent G2 gearbox shaft leak help for Newby

Postby BigJock » Thu Aug 10, 2017 1:23 pm

Hi all from new (but very old...) member.
Just did a deal to px my 1960 G2 for a larger G5 and it's due to go away tomorrow.
Sods law it's sprung a leak - a good one too - on stripping off right hand cover the lead seams to be twofold.
1) from around the gear selector shaft 2) from inside the shaft itself which appears to be hollow.
I can understand the o ring on outer shaft leaking but from inside the shaft????
Can anyone shed light on this asap please????
To change the o ring do you simply unbolt the outer gearbox cover??
What about the leak from the inner shaft??
Also by sitting over the winter I've now got no clutch - anyone help??
Regards
Jock
ps I've been lucky for the last few years with it and sods law the day before it goes this happens....

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Re: Urgent G2 gearbox shaft leak help for Newby

Postby clanger9 » Thu Aug 10, 2017 7:58 pm

Hi Jock,

There are 2 o-rings on the gear indicator shaft (which is inside the selector shaft).
There's also an o-ring in the outer case that seals the selector shaft. Some pics here:
https://www.ifixit.com/Guide/AJS-Matchl ... 77#s172050

Hopefully an easy fix!
1966 AJS Model 14 250 CSR "cafe racer"
1993 Ducati 750SS

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Re: Urgent G2 gearbox shaft leak help for Newby

Postby SPRIDDLER » Thu Aug 10, 2017 9:19 pm

BigJock wrote:Also by sitting over the winter I've now got no clutch - anyone help??


What exactly does 'no clutch' mean?
Does it not free?
Does it slip?
Does the handlebar lever not move?
If it's been unused over winter the plates could be stuck together and need to be freed.

Gissaclew...........
What if the Hokey-Cokey is what it's all about?

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Re: Urgent G2 gearbox shaft leak help for Newby

Postby Ozmadman » Fri Aug 11, 2017 7:33 am

clanger9 wrote:Hi Jock,

There are 2 o-rings on the gear indicator shaft (which is inside the selector shaft).
There's also an o-ring in the outer case that seals the selector shaft. Some pics here:
Hopefully an easy fix!
There is a mod for the outer o ring which is now a shaped seal instead, not sure of the part number off hand but it is the same number as the o ring but with and X suffix. Mine still leaks a bit from there despite o ring and seal changes!
Paul
1960 Model 8
1974 Yamaha RD250B US Model 6 speed

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Re: Urgent G2 gearbox shaft leak help for Newby

Postby shifter » Fri Aug 11, 2017 8:23 am

I bought the new type 0 ring seals gear & kick shaft from the club site fitted them to my daughters G2csr and the oil is staying in the box now no weeping at all
shifter
?

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Re: Urgent G2 gearbox shaft leak help for Newby

Postby clanger9 » Fri Aug 11, 2017 5:32 pm

Mine is nice & oil tight now around the gear change, but I can't figure out how the kickstart seal is supposed to work.
It seems to be designed to leak (unless there is a way to remove all end float from the kickstart shaft...). Perhaps I'm missing a shim somewhere?
1966 AJS Model 14 250 CSR "cafe racer"
1993 Ducati 750SS

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Re: Urgent G2 gearbox shaft leak help for Newby

Postby BigJock » Fri Aug 11, 2017 7:05 pm

Many thanks folks. Stripped down last night so finally know what I am talking about....maybe! 1 o ring missing from selector shaft - what a ¥£€₩ design - too used to working on oil free Japs. So now the leak is identified how the blazes do you get the end cover and that damn selector spring and pawl back in ?????

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Re: Urgent G2 gearbox shaft leak help for Newby

Postby BigJock » Fri Aug 11, 2017 7:07 pm

BTW lost the clutch because oil level had dropped and the pull lever inside rh cover had locked up.

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Re: Urgent G2 gearbox shaft leak help for Newby

Postby clanger9 » Fri Aug 11, 2017 7:08 pm

"With care" ;)
If you line everything up as per the photo, the cover should go on...
1966 AJS Model 14 250 CSR "cafe racer"
1993 Ducati 750SS

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Re: Urgent G2 gearbox shaft leak help for Newby

Postby BigJock » Fri Aug 11, 2017 7:20 pm

Its not playing ball
The spring just barely locates and as soon as you move the assy the pawl pivots ansd spring falls out

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