Gear Change issues

[DavidHill]

An update on the issues with getting 3rd and 4th.

I got access to an oven and the gears pushed out of the box nicely.  The issue turned out to be with part 38-20003 which slides on part 38-20001 to engage 3rd and 4th. It was jammed tight and would not side.  On inspection after taken them apart it was found a small area of the end of the splines was too tight on part 38-20001. I think it may be due to insufficient oil in the gearbox causing the part 39-20003 to become tight on the shaft.  Some very careful filing of the ends of the splines has solved the issue.  Next step is to clean everything, replace all bearings and reassemble.

One issue is that on removing the parts from the gearbox I managed to break the split ring 38-20009.  Does anyone have a source of new ones?

[Jay]

David, did you managed to fix the issue, plus also find a replacement ring?

[DavidHill]

Morning Jay,

yes i did find and fix the issue! (apologies for not updating sooner).  Part number 38-20003 is shown in the attached photo...that was jammed onto the shaft.  on removal I found one end of the internal splines was slightly discoloured indicating it had got hot for some reason (you can just see this in the photo). This was the end that was jamming, so i very carefully filed it down by about 0.5mm and then the shaft slid smoothly again.  So I put the gearbox back together (with the help of a replacement spring clip from Mike Raahague (Thanks again Mike!) . I fitted new bearings too. (see second picture).

I then took the Aprilia for a test drive and all was working nicely again - phew!.  I am now moving onto an issue with a hesitation (and cough) on accelerating from low speed in second...I suspect either timing/electrical or carb/fuel!