The early ‘73 layshaft had the non-chamfered high gear, if not pressed on fully it could do this - what is the history? You can install parts individually to find what causes the cover to hang up, I have often had to do this in converting 4 speed pre-unit to 5 speed. Tedious, but hey-ho.

 

When I remove the main shaft 1st & 2nd gear the inner cover pulls tight. Any thoughts?

 

As you are positioning the inner cover, use a little screwdriver and flick the selector quadrant up and down a millimetre or so this is so you are meshing with the teeth on the cam plate. You should feel it engage. Also when pressed home it should not be binding up.

 

The M/S 1st/2nd gear butts against the splines on the shaft, and the whole thing is the pulled to the right to clamp against the bearing when the kickstart ratchet assembly is tightened. So... someting is stopping the mainshaft from going all the way to the left? You still haven't given the history of what you've done, but it may be the mainshaft selector roller dropped out of engagement - hard to know from here.

 

What parts have been replaced?

 

If any!

 

I've replaced all the bushes in the gear box. I replaced all the bearings involving the gearbox. I replaced the layshaft due to a chipped gear but the replacement is the same part number. I replaced the inner cover because a bolt hole was puller out. The replacement is also the same part number. I'm using a transmission indexing tool to hold the shift quadrant. As I stated, when I remove the main shaft 1st & 2nd gear the inner cover fits so I believe the problem is with the main shaft. Any thoughts?

 

The inner cover part number you see is a casting number, the 5 speed bearing shield was machined out so the M/S 1st/2nd gear would go through to clamp to the bearing , yes?

 

Enjoy. Thanks for your help.

 

Hi Vic, Here is a drawing with dimension of my original '73 Tiger early layshaft with the narrow gear.
Also the new LF Harris layshaft. As you can see the splined shoulder is in different position. But inner cover went on fine. Shifting through the gears on bench, neutral would occasion click! 2n gear dogs were rubbing.

I ended up with .011" end play.

Cure ended up being custom thickness thrust washers moving the layshaft over just so. This allowed all work well. Has covered 12k miles so fat working good.
Don