Velocette 500, 4 speed reassembly, part 10

Final measurement, machining and assembly of reconditioned 4 speed gearbox. Some old parts rejected and used parts installed and checked for mesh and alignment.

[@gentlerowdy]

best velocette gear video form an another velocette fan from india

[@alanglen5902]

Many thanks

[@richardgarrett6154]

Most edifying and instructive - - - Thank you !

[@dducdude6315]

I can watch this stuff all day ! Many Thanks!

[@briangibbon8711]

Outstanding video Alan. I'm really grateful you patiently explained your expert knowledge to show us how to set up the 4 speed gearbox properly. Your helicoils and extended level plug screw are great mods too. Looking forward to your future videos.

[@TornadoCAN99]

Wonderful work Sir. I'm still sorting out issues on my new to me '54 MSS. After swapping all the clutch springs to correct length (had the shorter 7/8" springs in there), first test found too much grab....idling in neutral on center stand...bike would stall as I applied the brake. Made adjustment to free up clutch a little but then could not restart...many attempts when suddenly the kicker starter lever jammed solid, unable to be moved down from vertical no matter what I did with gear selector or rocking the rear wheel. Off with the kicker housing, both springs in good order, but I found some notching around the inner edge of the housing, where the gear teeth edges coincided. Further I did not find the "wedding ring" spacer/washer present up against the 1st layshaft toothed gear. Was hoping to catch of glimpse of that on your video but alas not seen. Have the spacer on order from the UK. Thinking is that the layshaft toothed gear was able to move outward enough to bite into the kicker assembly housing and jam the whole works up.

[@alanglen5902]

Thanks for the response. Make sure you check the straightness of the main shaft and also use the correct thickness outer cover gasket to help control end float. Also, I made a video on the clutch in video 7 and 8 in the "5 speed conversion series." This may be of interest. I have never heard of your problem before. Interesting. Have fun Alan

[@velocettevenomrestoration9577]

Alan, great vids and very informative. Looking forward to the roller starter vid

[@DH-fn8dj]

Great stuff, looking forward to next video!

[@briangibbon8711]

Hello Alan I wonder if you plan to do an oil pump removal/overhaul/replacement. I'm contemplating doing mine and seeing you fo it would be magnificent! Kind Regards Brian

[@alanglen5902]

Thanks. I bought a new oil pump from Dodkin in 1982. The original had got rusty and pitted as the bike was deralict when I bought it. I see the oil pump as being something which will never see the light of day in my life time as so far it has Only Ever had good clean 50 weight go through it. I expect no noticeable wear on the drive gear or the oil pump shafts. I remember the need to assemble the pump segments so that the outer surface remained completely cylindrical so it fitted nicely into the crank casing. I remember agonising about the orientation of the pump before I inserted it into the hot crank casing. I remember examining the crank case bore surface for scores etc. Sadly I have no photos of any of this. It easy to measure / assess the internal clearances. Happy to discuss further………I may have an oil pump buried away in an old crank casing….I may dig it out and have a look at it. Hmmmm. It might be worth a video. Alan

[@briangibbon8711]

@@alanglen5902 Many thanks for your prompt reply Alan - much appreciated. It does look quite a straight forward job but the intricacies of measuring tolerances, judging wear, improving tolerances, and reassembly and refitting would be very interesting as no-one has made a youtube video that I can find. I don't see an overhaul business advertised so I think a video would be invaluable. I'll take photos when I do it but I wouldn't have your presentation skills to make a video. Thanks again for the youtube videos you've made. Brian

[@graemewhit1208]

Been watching your videos as I have an odd fault in my 4 speed box. Can't suss it though, it's graunching occasionally, not always, when downshifting. Layshaft first is tight on the layshaft. Can't figure out what it is!

[@alanglen5902]

Well there are several elements to this: 1. Clutch adjustment 2. Bush clearances, both axial and radial, on main shaft and main shaft 3. Selector fork geometry / wear 4. Bent main shaft 5. Overall gearbox condition / end float set up 6. Etc etc It is easy to speculate, but very difficult to annreally is vey difficult to s

[@alanglen5902]

Sorry clumsy fingers I was just concluding that it is difficult to offer a sensible suggestion without seeing parts etc

[@graemewhit1208]

Thanks for the reply Alan. I had it all apart yesterday and have been inspecting for wear. It's not too bad, I think my problem is the layshaft fork contacting the back of layshaft third. Do you shim the layshaft, or shim behind the bearing? I thinkni could also do with replacing layshaft 3rd and second bushes and maybe the sleeve gear bush too. Does the layshaft 1st and 4th press together?

[@alanglen5902]

@@graemewhit1208 My strategy was to start with the lay shaft loaded into the casing with the ball race fully home. Then shim up the sleeve gear to ensure the full width of the sleeve gear / lay shaft gear mesh across the full width. Then shim up the lay shaft to control end float. Then work on the main shaft to make sure you have a first gear which is free on the main shaft without excess radial and axial clearance. The middle gears on the lay shaft are contained by press on outside gears. The 3 leg puller should pull these off, just make sure you get them back to where they are now when you replace them. It’s unlikely that they have moved since they were first installed at the factory?

[@graemewhit1208]

Many thanks. Sleeve gear engagement with layshaft 4th isn't great. Not measured but probably needs at least 1mm of shims. Thanks.

[@horacioaroza]

Hola como estas te escribo desde Argentina tenes una copia del manual detaller de la Velocette tengo una y necesitaria para revisar algunas partes , muchas gracias

[@alanglen5902]

Sorry. I only understand English.

[@horacioaroza]

@@alanglen5902 Hello, how are you? I am writing to you from Argentina, you will not have a copy of the manual from the Velocette workshop I have a friend who has that motorcycle and he can't get it and I would need to check some parts thank you

[@alanglen5902]

I have several manuals on this bike but have nothing easily transmitted electronically. Sadly I have no access to a scanner or a photo copier. The Velocette Red Book is very informative. It would be possible to buy the book and post it to you. Not sure how the finances of this would work out. I imagine postage to Argentina would be expensive. Please advise Alan