gearbox endplates

[wurzel]

Could anybody tell me if there is a definite difference in size between innocenti and sil endplates.
The reason I ask is I don't have a sil endplate to compare against the ones I've got.
I've started building an engine in an old , unused ,indian casing that I've had for a few years , the rear hub bearing is a Casa one and is fully seated .
I've put in the layshaft and that is fully home and I've started assembling the Cyclone box. The gear selector is in and the cluster is in with the shim fitted.
The gears all line up well and the smallest 0.8mm shim was fitted , also the layshaft shim and bearing. With these in place the gears spun freely until the
endplate was torqued down.
I've taken off the endplate and tried 2 others and exactly the same problem , so took out the shim and torqued it down again and still the same problem.
Checked all the usual things like layshaft sitting below the top cog etc..

Any suggestions please folks

Cheers in advance

[fairspares]

you say you have put in the layshaft and its fully home, but have you either put a rear hub or spacer tool on and torque the layshaft down?

[wurzel]

Had rear hub on and torqued down to make sure it was fully seated. Put he clutch spider on and dropped the holding tool in then removed the spacer
and replaced with hub and torqued it into position to make certain it was fully home. Still same problem.

[rosscla]

Have you tried torquing down the clutch spider?

This sometimes pulls the Xmas tree up a bit.

[wurzel]

Tried that too but same problem.

[vespanic]

I believe you have to fit the shim on the xmas tree before you torque the clutch (you mentioned you had taken it out after trying it the first time). I had the same problem with mine but found that once clutch was put in everything worked out fine. I too tried different endplates and although I didn't know it at the time this problem can happen with 4 speed boxes. It wasn't the endplates fault though it was mine. Stupid question but you have taken the shim out at the back of the xmas tree and put the supplied shim behind the clutch basket. There are also two shims so it might be something to do with that. You said you had used an 0.8mm but the two I had were 0.5 and 0.3mm. Good Luck

[wurzel]

Taken the endplate off and taken the endplate bearing out and the cluster is sitting too high into
the bearing aperture and that's with the cluster shim out and the endplate in position but not torqued down.
The cluster bearing bush seems to be sitting proud of the casing. Should this bush be flush with the casing?

[camel]

it does sit a little proud,can you fit the endplate without the xmas tree and see if the box locks,then remove the box and just fit the xmas tree and endplate...if both are free seperatly then the mis-matched endplate is your problem...or am i talking bollox...

[rosscla]

Usually the outer track for the cluster will sit out a little.

Worth trying the gearbox and cluster independent to see which is locking.

[Yanker]

I feel pretty confident in saying that it is 'probably' the Casa rear hub bearing if this is from the older batch that were not finnished correctly and are too 'tall' to shim up. Undersized gear shims from the likes of MB and Beedspeed may solve the problem. I'd start with a 1.0mm undersize shim to measure the extent of the problem and work from that. The missalignment between the cluster and loose gears will be minimal.