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.
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