poor1

Many thanks for confirmation

Did anyone manage to succesfully wire one up without a battery and regulator?

The answer is that on the outside of the circlip on the gear shaft there should be a washer (not a hardened one) against the circlip and then a wave washer before refitting the outer primary chaincase. Thanks Steve

Ive now had the primary chain cover off and other than the snap ring (outside circlip) there is nothing on the shaft between it (the circlip) and the outer case. I have routed around and found what I think may be the missing 'wave' washer. I gather from the input by 'pmk' there is supposed to be another thrust washer there as well. Any idea of the thickness/dimensions please. I'm going to Telford tomorrow and will hope to have a chat with Steve Sell who will probably put me right. Any observations would be appreciated.

duplicate

It's about ten years since I assembled it so I can't be sure whether I did install the snap ring or not. (I think we (UK) refer to snap rings as inside or outside circlips). However the the 'Jubilee' Clip (a screw driven hose clip) does hold the shaft in position. I have gone one better and sawn off an old gear change pedal and put that on the spline on the other end of the shaft for the time being and that is probably a better engineering solution than using a Jubilee clip I suppose, but I will remove the clutch side case in due course to fix it properly as it's seems logical that is the root cause,. Many thanks

Ive now located a chain thanks. Will certainly go to the Ludlow show in february

Thanks for the extras bit of information

I'm delighted to say that a tap on the end of the shaft seems to have been the solution. It moved inwards by about half an inch and (without starting the engine) the gears seem to be selecting OK. I've also freed the clutch and it seems to working as it should. It may well have had the clutch plates replaced with Barnett but I ould not know without taking it to pieces again. Trialsfun speaks of Marimar Ossa. When I googled it comes up as a Spanish site but not able to find any products. Is there a good British supplier. I know now that I will require anew rear drive chain. Any recommendations as to grade and type of oil for the gearbox please? I need to get on and complete the wiring so that I can start the engine. I have a full lighting set than I intend to install. Can this be installed with or without a battery?. You have all been so helpful and I'm most grateful. I think I shall back here for more advice as I press on. Thanks very much for your help so far.

Thanks for the extras bit of information

Thanks for the extras bit of information

OK that's very helpful. I'm relieved that my posting has caught your eye. I will follow your suggestions. With the passage of time I don't remember exactly how I assembled the engine and gearbox, but am I correct in assuming if I need to get at the selector mechanism the whole engine has to be split at the crankcases and that it cannot be accessed without removing the engine from the frame.? No it has not been started, I simply assembled the engine and gearbox very carefully, or so I thought, and put it in the frame. I wonder whether starting the engine, which requires further work to complete the wiring, would stir the thing up?. When (if) I get to the stage that i am able to rectify the gearbox I will look at replacing the clutch plates as suggested.

I've got an Ossa MAR with a lovely alloy tank which has been little used. I bought it about 10 years ago completely disassembled (everything including the engine, gearbox, rims and spokes - everything to it's last component). I put it together very carefully and had everything either polished, powdercoated and replaced with stainless. I don't remember much of the detail, but am now trying to get it finished. The engine is installed in the frame but moving the gear lever up or down does not select a gear and does not seem to engage with anything. Two questions: Am I going to have to take it all to pieces to get at the gear selectors and Contrary to my experience with the old British bikes when I operate the kickstart lever and disengage the clutch this has no effect and the kickstart which will still turn the engine over. I see from the workshop manual it is what it describes and a constant mesh gearbox. Is this something to do with it?. I've got a workshop manual. I would be grateful if someone could point me in the right direction.