AJS & Matchless Owners Club

I filled the gearbox with oil to control the operation. But the oil immediately spread under the bike. I took the cover off to look. It misses the complete lower part of the seal ...

I will order a new seal. But how to reassemble the cover? It is necessary to reposition the pignon of the kick but how?




Ruddy

You have to leave the kickstart lever on the shaft. Use this to wind up the spring to the correct position, then holding the cover and kickstart lever, fit the cover.
Dave.

Ruddy.
There are helpful details on pages 41 and 42 in the '54 manual here:

http://archives.jampot.dk/book/Owners_m ... ingles.pdf

Hello Dave & Spriddler

Many thanks! I order tomorrow the gasket kit.

Regards, Ruddy

dave16mct wrote:You have to leave the kickstart lever on the shaft. Use this to wind up the spring to the correct position, then holding the cover and kickstart lever, fit the cover.
Dave.

I try to put the cover back with the kick spring tightened but after the kick is blocked and do not move ... the gear of the kicker must be positioned how? I do not understand.

rudelan wrote:

dave16mct wrote:You have to leave the kickstart lever on the shaft. Use this to wind up the spring to the correct position, then holding the cover and kickstart lever, fit the cover.
Dave.

I try to put the cover back with the kick spring tightened but after the kick is blocked and do not move ... the gear of the kicker must be positioned how? I do not understand.

The concave edge of the kickstart quadrant (just to the right of the red arrow in your second photograph) needs to be positioned against the machined aluminium peg on the gearbox inner cover (bottom left on your first photograph). The spring should be wound up but NOT fully tight at this point as the quadrant still need to rotate another half a turn when the kickstart lever is used.

I tried but the kick is still blocked. No speed engaged.
I disassembled the chaincase. Surprise! The magnet sprocket nut is gone and it gets stuck in the primary chain ... That's why everything was blocked. Thanks again for the help.