Replacing RH cover on BA gearbox on VH

[Alan G]

I have the side off the gearbox, complete with kick started and gear lever.

When putting it back the 'sector' (correct name? ) was connected to the cover but had rotatated and was hanging down out of place. I pushed it up and hoped for the best - and put the cover on. Before doing any more, I tried the gear box and 1st and second seemed to engage fine, third and fourth, not so much.

So I figure the sector and its shaft should have stayed in position with the bike when the cover came off. The shaft pulling out of the gear lever shaft. Is that correct?

So... how do I line everything up correctly and re-assemble? i'm guessing I pull the sector off the cover, and align it correctly on the box, then push the cover on again. But what is the correct alignment?

This is the bit I am calling 'sector'

[Roger Gwynn]

It is critical that the 'O' marks line up on the sector and selector drum. it is one of those jobs that can go together the first time or the 20th time! I can never remember which bits should be in the outer case and which on the gearbox but certainly the sector should be on the gearbox.

[markus.nikot]

During assembly, the sector must be fitted into the gearbox housing. Only then can you see both marks and align it correctly.

[Alan G]

All done. Found a video which showed me the marks that needed aligning.

For anyone else in the future who has the same issue:
This is what my case looked like:

The Sector is the ratchet looking thing. You can pull that off the case, it comes with its own shaft:

Push that into the gearbox so that the mark on the pinion aligns with the mark on the sector:

If the mark on the gear pinion is not in the correct position to line up, put the sector on, put the case on, and use the gear lever to to change gear and change the position of the mark. Then take the case off again and see it the mark is where you need it, if not, repeat until it is correct. Took me several attempts to get it aligned.

[Pete.Silson]

This afternoon I had to remove the outer cover from my CP box (mechanism is identical to a BA) to replace the kickstart bump stop. The sequence of events was:

Put the box in 3rd gear, remove the gear lever and the bolt that aligns the spring box and remove outer cover.

After having checked the alignment of the index marks, the complete selector (including spring box) can be assembled in the inner cover. Leaving the kickstart shaft in the outer cover (with the kickstart attached to hold the return spring) fit the outer cover.

Lastly replace the gear lever and, using this, align the spring box and replace the bolt. No trial and error necessary and the whole job, start to finish, took 30 minutes.