Gear Changer Assembly?

[Dr. Frankenstein]

Does anybody have a photo of the position or set-up of the gear-changer on a '63 CA77E? Or installation instructions for that part?

I've got my engine rebuild coming together nicely, but all I have for a reference re: the gear changer install is the parts diagrams and a teeny 2" x 2" black and white, over-contrasted picture of the location of the gear-changer in the repair book - *not the big forked shift-shaft, but the two levers with a spring between them, with a big flat-end bolt that goes into the crankcase and seems to attach from outside the case...


Does that part get inserted into the transmission BEFORE you seal it up, or can I do it afterwards? I really don't want to cement the two halves together as the book tells me to after I have installed the transmission only to find I need to get back in there again. The instructions seem to jump around to the various parts and don't really seem to follow any sort of "flow".

[DJM]

The big bolt goes in AFTER you have put the two crankcase halves together.

You need to make sure that the kickstart shaft is in the correct position before you screw it in though.

There is (usually) a small notch ground in the end plate of the kick-start shaft, you need to position the shaft so that this notch is visible through the 'window' between the primary drive and the gearbox and then insert the large diameter bolt. If it won't screw in to the full depth by hand you have something wrong.

The round section on the end of this bolt disengages the kickstart pawl when the shaft rotates to its 'at rest' position but it won't do this until you fit the RH cover with the kickstart shaft and kickstart return spring correctly assembled.

None of this is covered particularly well in the shop manual.

[Dr. Frankenstein]

Thanks DJM; that makes it a bit clearer, I might be able to work with that - so the kickstart SHAFT goes in BEFORE you close it up?

Do you have a picture you can send...? I'm kind of mystified as to how the gear-changer attaches to the kickstart shaft.

[Dr. Frankenstein]

I'm interested in how the Shift Drum Guide and Stopper in the Gear Change section of the parts manual go together, with that spring mounted between them...plus of course the construction and placement of the shift-shaft...