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Any else have any particularly important tips on this conversion?

I've picked up some empty cases and will prepare them for the cluster. I have the Nova instructions.

The existing box will occasionally drop out of gear and the kickstart occasionally jam as well as the gap between 2nd and 3rd too big.

Does the kickstart jamming relate to a specific issue (I understand it is not uncommon on pre-unit BSA boxes) is it just wear in the ratchet, bushes or a bit of everything - ie has anyone a reliable cure for kickstart jamming that I can use to eliminate it on a gearbox rebuild (I was going to use my existing outer cover and speedo drive.

I understand that the casing needs fettling and the drive side bush gets replaced directly with a needle roller, although there is no mention of a thrust washer which is usually required in my experience?

I will keep the touring footpegs but go for up for up and down for down (my Triumph days hangover!).

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Hi Neal,
That jamming kickstart issue is usually from the teeth on the main shaft gear being gnawed down in diameter from years of use so that the short lead in tooth on the sector gear just jams against the main shaft gear tip to tip. That's where the jamming often comes from. Sometimes, grinding the short tooth even shorter helps but a new gear is best.

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The Nova cluster comes with all thrust washers required.
The jamming kickstart is mainly down to a worn ratchet gear, relatively cheap to replace.
You will need to do a bit of trimming of the slot in the sandwich plate, some main casings need a tickle with the Dremel too

The Nova 5 speed has transformed my Goldie rep


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Andy that is really helpful, just what I needed to hear.

I think the drive side needle roller drops in the the existing case size but the timing side needs line reaming to accept the needle roller?


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