Sleeve gear bushes replacement

[BSA500]

Hi,
My sleeve bushes are in need of replacement-oil everywhere,clutch moving around etc. I have a couple of spare gears so I am trying to remove the old bushes and then put in the new. I am using the tool usually used to draw up the fork legs so its very tough but the bushes just will not budge.What is the general method everyone uses heat?violence? or......

Thanks Andy(who has enough dealing with riding every day,dead dynamo and mystery vibration prob the clutch )

[KiwiGF]

I've done this job and took some pics which if no one beats me to it I'll post them up

From what I remember the bushes I took out were split and not that hard to out but pattern replacements were not split but went in easy enough using a vice

[trevinoz]

I machine the bushes out in the lathe.
 
  Trev.

[Brian]

Depending on what equipment you have available to you there are a few ways to remove them.

Use a lathe as Trev suggested which is what I do.

If you dont have a lathe you can use a threading tap, find one that screws into the bush and then knock or press it out.

If you dont have any of that stuff a hacksaw blade held in the hand will work. Just carefully slot them until they come loose. The gear is hardened so at worst you will only scratch the gear if you go too deep.

After you have fitted the new bushes, making sure you have lined up the oil holes in the inner bush, you may have to ream them to size. If they do need reaming then once again if you dont have a reamer then you will have to take them to a engineering place. Reaming the bushes is a simple job so they shouldnt charge much to do it.

[Goldy]

If you slide a hacksaw blade through the bush and then assemble the hacksaw around it, you can saw partly through the bush so that when you try to remove it it will collapse inward. all the best Goldy.

[BSA500]

Used the hacksaw trick one out already. But these bushes are steel backed which makes it a little more interesting. What is the running clearence of the shaft when its reamed?. Also any one know any good engineeering shops near Tonbridge kent.
thanks Andy

[KiwiGF]

Here's some pics of tools I made up to remove and replace the sleeve bushes - the most important bit is the small stepped (shiny) colIar which is a fairly good fit inside the bushes and sleeve gear.

I got the new bushes  from Draganfly.

It sounds like you will have got the old bushes out using the hacksaw method by the time you see this - but I thought anyone searching the forum might find these pics useful. My bushes pressed out quite easily using 10mm studded rod, but as the pic shows one was installed slotted for some reason.

The old bushes had 015 clearance on the mainshaft but I do not know what effect that had on the gearbox leaking/whining etc as I have not run the bike yet. I noticed the excess clearance when removing the clutch.

As regards the correct "new" bush clearance, I've done mine at just over 001, but up to 002 would prob be OK.  I think there is a BSA document on plain bearing clearances somewhere on the net. I'll try to find it.

[BSA500]

Right the bushes are out and they were both steel backed and one was stamped with VP. I reckon they are BSA supplied ones and also one was split lenghtways. I have decided to bite the bullet and get a hand reamer and pratice on an old sleeve gear then do it myself. Just to check the mainshaft dimension is about 0.810 thou?.The reamer size I would need is 25/32-27/32(£18.00 all in from Tracy tools cheaper than paying a workshop)  Good idea??

[Pilgrim]

Hiya,
Don't know if this helps?
www.mistgreen.com/service.htm
look for service sheet 702
Cheers.

[BSA500]

Thanks for that. It seems to suggest the shaft itself is 0.810 so the reamer I was looking at is the right size range. Hang on reading another thread suggests the shaft measures 0.75 but the old sleeve gears I have are approx .810. can some one please measure the mainshaft of a swing arm gearbox pretty please before I buy a reamer.
many thanks Andy

[wilko]

Just take it to a local engineering shop? No point in buying a one use reamer.

[KiwiGF]

I'll check a mainshaft for size later tonight but I reckon you should buy and fit new bushes before buying the reamer as you might not need to ream the bushes, especially if your shaft is worn a bit under?

Added an extract from the 702 service sheet as mentioned in a post above, with the "pinion gear" bush tolerance at 0.812/0.813.

[BSA500]

Its actually cheaper to buy the reamer than take it to a workshop(if one even existed round here). Also seeing as I use her every day for work I can do the work to my timescale. KiwiGF if you wouldn't mind that would be great.
Andy

[KiwiGF]

My mainshaft where it fits inside the bush is 0.809" diameter

Did I really just say that:-)

[BSA500]

Thanks your a star that means the reamer I was going to buy will be right.
Andy

[KiwiGF]

Most likely BSA chose 0.812/813 as 13/16 is midway at 0.8125 so they could use a std 13/16 non adjustable reamer to get the reqd bush dia and machine all the shafts slightly under 13/16 to get the necessary clearance

The shaft you have is probably worn so you might want to make the bush slightly under 13/16

[BSA500]

The reamer I have chosen go's from 0.78 to .84 so should have that covered 

[BSA500]

Well the fun never ends does it. Just installed the bushes and found out the short bush of the pair is,well,short by 10 mm. Of course this means there is a gap. My question is would that really be a problem as I have it planned to do the gearbox next weekend and cannot afford to order replacemnet bushes in time reasons.

[KiwiGF]

If you look at my earlier pics the bushes are the same length and I would not use them if they have been supplied wrong

What does the supplier say about the bushes they have supplied?

Draganfly supplied mine ex stock

[BSA500]

These were from Draganfly and every order for parts from them recently have been wrong. The rocker feed that took 2 months then was for a b25 to ordering 4 sprocket nuts and paying for them and getting only one. As for the bushes my next door neighbour an ex engineer said it should be ok if the shaft is supported each end. As I said before next weekend is one of the few times I can have the car for work while I repair the box so it has to happen. Draganfly are not open weekends so I would have to wait until Monday to contact them. On the website it states you should have a short and long bush so I assumed that was right it seems not. It would take to long to get new bushes and meet my deadline. Ho hum