Gege Blog 22.1 Gearbox A is back from Italy (f) .pdf



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Gege Blog English –

22.1 – GEARBOX "A" is BACK FROM ITALY - La boîte "A" est de retour d'Italie

Tuesday, November 15, 2016
The crate from Italy arrived this afternoon 15/11, shipped on 9/11,... thank you Fedex!.

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Unpacking:

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we are like kids in front of Saint Nicolas gifts!

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The cover that comes back from far away !..., still wrapped steering gear:… the rest of the root of olive tree , waste bases gear
levers and the adjustment tool for steering gear eccentrics.

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Fitting the cover:

.

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A beautiful ball in olive wood (Andre does not want to use this time for fear of dirtying before it is processed ...)

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, so we will use the teak ball for testing:

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Gear change test, it's perfect!

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The tool for tightening the drum nut on transmission (and we still don't know which torque ...):

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And a small video

:

Saturday November 19, 2016

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Today, reassembly of the "accessories" on the box ...
We start with the transmission brake ...

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Final touch up of paint

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final check of nut tightness

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pinning,

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degreasing of the conical end of the primary shaft with acetone; fitting the brake shoes .

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The "friction pads" 11519 between the jaws and the "brake key" 11510 are somewhat distorted , straightening in the vise; that
is good now: .

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Installation of the key after placing the two adjustment washers and the conical crushing washer (the bearing being sealed;
the oil-trower ring has been turned. See here during the first "blank" mounting ) .

Degreasing with acetone of the drum cone and installation

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The ball nut is provisionally tightened; we are waiting for the stop 12130. Presentation of the “flector “ ( flexible coupling )
with the tripod "to see"

...

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We move on to the lid of the box, and we can't help but take it apart to admire Michel's work ...

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The famous 11814 pin expertly machined by Michel

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Blocking with the impact driver (but without percussion) screws forks springs (and thank you Andre for the close-up on my
skull!)

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Hermétic:, installation of the joint. We will put (maybe) hermetic on the other side when we are sure that it is no longer
necessary to disassemble ...)

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Lubrication of the ball joint housing :, fitting of shell 10235 , spring 10234 , nut 10233

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We then move on to the pedals. Its new chromed steel shaft.

,

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pedals re-bushed as new: .

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There we see that it will be necessary to machine washers of 18 x 28 in order to perfectly center the clutch fork, and to absorb
the lateral play of the pedals on their axis:

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The M8 studs that we had mounted on the back of the cover (and not the M7 due to the "RS" brake coupling assembly) are
too short. André finds other M8 "period" studs that are longer, but you have to extend their thread: and then cut them

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We then mount the brake lever with the "RS" assembly, but I think we will come back to it ...

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Before leaving the garage, some photos "for your viewing pleasure":

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And a video. The nesting of the two primary half shafts is so fair that they train (slightly) mutually without even the dog clutch,
but it will run in:

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Tuesday December 6, 2016
The rear wheel brake lever has too much play on its axis 11741 (fixed on the gearbox cover). The "pendulum" clearance at its
lower end causes the release of the lug on the handbrake rack. Solution: slightly rectify the shaft and bush the lever, still a job
for Michel ( we could have thought of it earlier!). Some photos to explain the problem to Michel, before sending him the lever,
the shaft and the rack for correction .

..

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. We wonder what can be used for this big piece of metal at the bottom of the brake lever, is it "original"?

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Wednesday December 14, 2016
The adjustment washers (18x28mm in different thicknesses) for the bottom bracket arrived today. Felt marking on the axle for
perfect centering of the clutch fork:

A 2.55mm thick washer should fit on the opposite side of the pedals:

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Re-installation of the fork key in the direction we had found it during disassembly: fitting and tightening (temporary, it will
probably be necessary to disassemble to couple the gearbox to the engine ...) of the nut, it's perfect ...

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Fitting remedial washers to correct lateral play of the pedals: 0.70 mm between accelerator and brake

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test of a 0.78 between accelerator and clutch, it is too much:

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I replace the 0.70 by the 0.78 between brake and accelerator, and a 0.50 between accelerator and clutch:,

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it's perfect, no more play!

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Michel has finished work on the handbrake lever, the package is on its way, we are impatiently waiting for it to finally finish
this box ...

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Friday December 16, 2016

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Arrival of the package this afternoon (here the parts taken out of the strong cardboard tube to protect them) ...

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Rectification of the small diameter of the shaft, and apparently careful cleaning of the rest if we compare with the state of this
shaft 11741 during disassembly (on box F)

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The bore of the brake lever bushed "as tight as possible" , the lug rectified:

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The rectified rack:

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Ready to be fitted. ...

Saturday December 17, 2016
Last straight line for the box ...

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We start by giving the gear lever the correct angle so that it does not interfere with the brake lever. André has determined
from various sections found in the literature that he must make an angle of about 60 °. In addition to the backward angle, we
bend it very slightly to the left ...
Heating torch, it folds very easily .... Cooling, and a layer of paint dried with a heat gun:

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Final positioning of axis 11741 in the box cover (with a practical conical crushing washer found in the parts: so it is tight and
you can pin it easily):

We then permanently install the drum driveline:

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tight to 60 Nm, with the aid of the brake

:.

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Folding down of the washer, and as the anti-rotation lug seems very fragile to us we mounted the large ball joint with Loctite .

..

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Reassembly of the cover and the lever

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, pinning

Installation of brake lever and brake "RS coupling "

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There is no more play at the base of the brake lever, the lug fits perfectly in the rack, once again congratulations and thank
you Michel! And André is very happy: the tightened brake lever is parallel to the gear lever in neutral:

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Some pictures of the fitting of the "RS": system. The play found in the rod with oblong hole was resumed ... with blows of
mass!

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To end this saga, some general photos of the beautiful machine ...

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THE END

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