To Remove Gear Box End Plate For Examination Of Gears; To Re-Assemble - Matchless G3L Maintenance Manual

Remove the nut and small spiral spring securing small gear Indicator disc from the cam
barrel spindle.
Next remove the five cheese head screws by which the K.S. case cover is secured to the
gear box end plate.
Withdraw the cover about ½ inch, holding the K.S. pedal firmly while doing so.
Now swing the K.S. crank round until it can be tied to the foot change lever.
prevents the K.S. return spring unwinding and facilitates re-assembly.
The entire cover can now be removed.
Re-assemble in exactly reverse order taking care to avoid damage to the paper joint
gasket.
NOTE—The position of the various cheese head screws securing the K.S. case cover are
as follows :—
In the top position, screw measuring 38 inches under head.
In the bottom position, screw measuring 2d inches under head.
In the rear position, screw measuring d inch under head.
In the front position, top screw measuring 18 inches under head
In the front position, bottom screw measuring 1a inches under head.
TO REMOVE GEAR BOX END PLATE FOR E X A M I N A T I O N
OF GEARS
Remove K.S. case cover as already described.
Remove split pin securing both gear striker shaft pins and withdraw the pins and also the
cam barrel in which they operate together, with the spring loaded conical ended
plunger which engages depressions on the underside of the cam barrel.
Remove the mainshaft end nut and draw off the K.S. ratchet driver, pinion, spring and
bush upon which the pinion is mounted.
Remove the three cheese head screws by which the end plate is secured to the gear box
shell and the end plate is then free to be withdrawn leaving the gears and gear striker
shafts in situ.
Take care to avoid losing the steel ball fitted in the end of the mainshaft and interposed
between the clutch actuating lever and the clutch thrust rod.

TO RE-ASSEMBLE

If gears have been disturbed insert them in their proper order with slider shafts in
correct location and apply end plate with paper joint gasket in position.
Re-fit the three cheese head screws and firmly tighten down with a stout screwdriver.
Then insert conical ended plunger and spring and apply the gear selection cam barrel
with any one of the depressions on its underside engaging with the conical end of the
spring loaded plunger.
Next insert the selector shaft pins and secure each in position with its split pin.
Complete the assembly in reverse order of dismantling ascertaining, before applying the
K.S. case cover, that the ball is inserted in the end of the mainshaft.
Fill to correct level with one of the recommended oils and lastly re-fit the gear indicator
disc and adjust its position to give correct indication of gears.
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