Removing Champion reverse on a 5 speed

[Lee H. Mann]

The toughest part is removing the gears from the shaft and may require a little heat to soften the glue

Thanks Lee. This is the information I’m after. I think the problem is with the detente as it’s moving the leaver is the issue. The gears shouldn’t have to come off. I think to get the trap door of with the linkage and the idler you remove the grub screws then undo the big Allan head bolts. Remove the trap door with a puller. That would leave the gears on the shaft right ?

my main concern is the grub screws I remember were plastic and the shafts are shimmed to give the right clearance. That shouldn’t change but think the crush washers would need replacing. Am I talking bollocks ????[/QUOTE]

If you examine and determine that the lever is bent slightly, you may be able to straighten it enough without removal. To remove the lever does require removal of the trap door.

When removing the big nuts with the wave washers and shims beneath, there is a plastic (nylon) washer beneath. I use a dental pick to remove everything just so that they don't fall out while working on the cover. Keep these washers and nuts separated from main and countershaft. Don't mix them up !!

You need to make a puller to remove the trap door.

The nut has 2 screws each and they are 1/4"x 20 nylon grub screws. Might not be available in the UK. I have gone to the hardware store and bought long nylon screws and cut my own replacements.

[knockdolian]

If you examine and determine that the lever is bent slightly, you may be able to straighten it enough without removal. To remove the lever does require removal of the trap door.

When removing the big nuts with the wave washers and shims beneath, there is a plastic (nylon) washer beneath. I use a dental pick to remove everything just so that they don't fall out while working on the cover. Keep these washers and nuts separated from main and countershaft. Don't mix them up !!

You need to make a puller to remove the trap door.

The nut has 2 screws each and they are 1/4"x 20 nylon grub screws. Might not be available in the UK. I have gone to the hardware store and bought long nylon screws and cut my own replacements.[/QUOTE]

Thanks again. Sounds like you have don this before. Why, did you have the same issue. I made the tool to remove the original trap door. Might still have it. As far as I remember it was a bit of two inch flat with some holes. So as long as I keep all the shims together and in the right order for the right shaft I should be able to torque the big Alan caps and jobs a goodun yes ? Any reason why the grub screws are nylon . Can they not be steel ?

[Lee H. Mann]

Thanks again. Sounds like you have don this before. Why, did you have the same issue. I made the tool to remove the original trap door. Might still have it. As far as I remember it was a bit of two inch flat with some holes. So as long as I keep all the shims together and in the right order for the right shaft I should be able to torque the big Alan caps and jobs a goodun yes ? Any reason why the grub screws are nylon . Can they not be steel ?

Screws need to hold the nut like a nyloc. You shouldn't have to disturb the gears.

As I said earlier, sometimes the rider doen't push the lever down and tries to force it, bending the shaft.

Happens usually to the second owner.........

[knockdolian]

Screws need to hold the nut like a nyloc. You shouldn't have to disturb the gears.

As I said earlier, sometimes the rider doen't push the lever down and tries to force it, bending the shaft.

Happens usually to the second owner.........

6 years I fitted it. No issues. After second owners had it fo 3 months. It don’t work. Thanks again.

paul

[Lee H. Mann]

6 years I fitted it. No issues. After second owners had it fo 3 months. It don’t work. Thanks again.

paul

Paul, did you get it squared away yet ???

[knockdolian]

Hi Lee, thanks for your interest. In a word no not yet. The chap who owns it is a friend but lives about 150 miles away. I will at some point . I was re reading your reply and I think what you say about bent leaver is on the money. I’m guessing it would still have to all come off to get it out or will trying to straighten it in situ make things worse ? Hopefully I can get up there over Christmas when I have some time off and see what’s happening.

Thanks again

Paul

[knockdolian]

Hi all, sorry for the late reply. The problem is now sorted. I wasn’t involved in the repair. Turns out the roll pin that holds the leaver on had come out and was locking up the mechanism. Eventually the leaver came off. My brother made a trap door puller , fitted a new roll pin and all is well. 👍

[Gorilla]

Hi all, sorry for the late reply. The problem is now sorted. I wasn’t involved in the repair. Turns out the roll pin that holds the leaver on had come out and was locking up the mechanism. Eventually the leaver came off. My brother made a trap door puller , fitted a new roll pin and all is well. 👍

Thank you always good to have a followup to close out an issue.