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Thread: Removing Champion reverse on a 5 speed

  1. #11
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    Quote Originally Posted by knockdolian View Post
    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 Iím after. I think the problem is with the detente as itís moving the leaver is the issue. The gears shouldnít 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 shouldnít 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.
    Jim Murphy
    Lehman Tech since 1998
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    Lehman & Champion Dealer Owner Operator
    Iron Butt Rider 2001

    WHEN HELP IS OFFERED, A SIMPLE "THANK YOU" IS APPRECIATED.

  2. #12
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    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 ?

  3. #13
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    Quote Originally Posted by knockdolian View Post

    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.........
    Jim Murphy
    Lehman Tech since 1998
    Champion Tech since 2005
    Lehman & Champion Dealer Owner Operator
    Iron Butt Rider 2001

    WHEN HELP IS OFFERED, A SIMPLE "THANK YOU" IS APPRECIATED.

  4. #14
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    Quote Originally Posted by Lee H. Mann View Post
    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 donít work. Thanks again.

    paul

  5. #15
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    Quote Originally Posted by knockdolian View Post
    6 years I fitted it. No issues. After second owners had it fo 3 months. It donít work. Thanks again.

    paul
    Paul, did you get it squared away yet ???
    Jim Murphy
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    Lehman & Champion Dealer Owner Operator
    Iron Butt Rider 2001

    WHEN HELP IS OFFERED, A SIMPLE "THANK YOU" IS APPRECIATED.

  6. #16
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    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. Iím 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 whatís happening.

    Thanks again

    Paul

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