Gearbox outer case assembly Clearance

Samuel Whittle · Jan 16, 2021

marshg246 said:
You're there so I'm not saying your wrong, but I still think it is wrong. The way to tell for sure is the mark the inner cover where the cable enters the outer cover. Remove the outer cover and the actuator arm. Then using a flat piece of metal against the inside of the slot the actuator rides in, see how you line up. If that's right, the other possibility is that the rod, ball and actuator are not properly engage and the actuator is too low - it seems a little low in the picture. I realize it worked with the old cover but there are a lot of variables - rod adjustment, cable hole angle, cable hole placement, inspection hole placement, and of course, the wall thickness you are thinking about. My concern is that you have a long way to go to get the cover on and I've replaced them without any trouble.

Yeah, I think it is definitely worth some further investigation. I appreciate the followup. I will keep digging and let you know what I find out! I agree that it seems weird for it to not just "fit". Any time i buy parts from AN and they aren't working, I assume there is something else I should be paying attention to haha

Hortons Norton · Jan 16, 2021

It looks like the ball is not in place. Try lifting the arm up and moving in further to get the ball in place.

TomU · Jan 16, 2021

Samuel Whittle said:
Any time i buy parts from AN and they aren't working, I assume there is something else I should be paying attention to haha

I got a new selector fork from AN and it didn't fit right so don't assume they are perfect

And what exactly is the problem? The lever does not go down that far in operation

Samuel Whittle · Jan 17, 2021

TomU said:
I got a new selector fork from AN and it didn't fit right so don't assume they are perfect

And what exactly is the problem? The lever does not go down that far in operation

Haha well the thread started out as the new outer cover I got fouling out on the clutch lever. I thought that was strange but it sounds like other users had bought them from AN and also had to dremel out the inside. The new outer cover is almost 4mm shallower in some places than my old one. Then the thread became a discussion about the position of the clutch lever itself. Both subject have been beneficial for me. I adjusted the clutch lever slightly at the advice of users. Still faults but it’s a better position nonetheless. Also confirmed that my outer case is t the only one with these shallower dimensions.

olympus · Jan 19, 2021

Samuel Whittle said:
Glad it wasn’t just me. So yours too was considerably shallower but you just shaved out the inside? Okay I may just go that route then. Thanks!

I only had to remove about 2mm of Material

olympus · Jan 19, 2021

marshg246 said:
You're there so I'm not saying your wrong, but I still think it is wrong. The way to tell for sure is the mark the inner cover where the cable enters the outer cover. Remove the outer cover and the actuator arm. Then using a flat piece of metal against the inside of the slot the actuator rides in, see how you line up. If that's right, the other possibility is that the rod, ball and actuator are not properly engage and the actuator is too low - it seems a little low in the picture. I realize it worked with the old cover but there are a lot of variables - rod adjustment, cable hole angle, cable hole placement, inspection hole placement, and of course, the wall thickness you are thinking about. My concern is that you have a long way to go to get the cover on and I've replaced them without any trouble.

My operating arm was indeed accurately aligned with the cable aperture and i have the AN tool for tightening the collar.
With the old cover the arm cleared... with the new it didn't, I'm sure AN have seen this issue before due to the willingness to replace it

Gearbox outer case assembly Clearance

Samuel Whittle

Hortons Norton

TomU

1972 Roadster

Samuel Whittle

olympus

olympus

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