Introduction
This guide will show you how to remove the gearbox from a 250cc AJS Model 14 / Matchless G2 or a 350cc AJS Model 8 / Matchless G5 motorcycle (all years).
You will need a set of Whitworth spanners or sockets and a decent flat-bladed screwdriver.
Note that the bike featured in this guide has a few modifications from standard, so your bike may look a little different in places. The basic technique remains the same, regardless of which model of Lightweight you have.
What you need
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Remove the six screws holding the primary drive cover on.
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Lift the cover away. Note that the cables to the alternator will still be attached, so make sure the cover is supported and not pulling on the cables.
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Unscrew the clutch springs with a piece of flat metal.
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Lift off the clutch cover and withdraw the clutch operating rod and clutch plates.
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Engage a gear and undo the clutch retaining nut. This is likely to be tight; it will undo more easily if you "shock" it loose with light hammer taps onto a socket driver.
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Remove the kickstart.
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Remove the gear position indicator (if fitted) and the gear lever.
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Remove the exhaust.
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Remove the link from the rear chain and move it clear of the gearbox sprocket.
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Drain the oil from the gearbox.
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Undo the four screws holding the right side cover on and remove it.
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Undo the two screws holding the inspection cover on and remove it.
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Slacken off the clutch cable completely at the handlebar end and release it from the clutch lever.
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Push the cable through to release it at the gearbox end.
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Look in through the gearbox inspection hole and release the cable from the operating fork.
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Withdraw the clutch cable from the gearbox and put it to one side.
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Remove the two barrel bolts from the gearbox retaining bands.
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Remove the two nuts holding the tensioner in place.
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Withdraw the tensioner and the two spacers either side of the gearbox mounting tab.
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Remove the two nuts at the rear of the mounting plate.
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Lift the mounting plate away.
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