To remove 3rd and 2nd gear from the main shaft, the “Spring Ring” first needs to be removed.

For the spring ring, it’s a one way ticket as there appears to be no tool to remove it undamaged.

The general consensus from the knowledgeble folks on the S2 Forum, is that a series of screw drivers driven down the splines of the shaft to lift the spring ring out of it groove is the best way to go.

So here we go….

Spring ring: the metal ring inside the teeth of 2nd gear. You can just see the gap.
Terminal screw driver and brace….. this didn’t work
“Dog killer” screwdriver and brute force….This sort of worked….
This DID work with the assistance of some large piers… which left my hands too full to take pictures
There should definitely be a special tool to remove the main shaft spring ring
With the spring ring removed, 2nd and 3rd gear can be removed from the shaft. The mainshaft bush is toast.
How the gears and bush should relate to each other
The bush has failed… at some point it has become “bound” on the inside 3rd and 2nd gear and sheared. The bush is seized inside 3rd gear (top right) and needed drifting out
Soft jaws in the vice and ready to drive the bush out
…and to do this, we use a suitably sized socket as a drift… this in turn is hit with a hammer
Halfway through the job…
All parts of the mainshaft bush removed from their respective gears. The should be one piece of metal


Next up:

Removing the reverse gear idler.

To remove the shaft holding the reverse gear in position, the manual recommends “gently heat the casing”… so this is what i did. Not sure my blow lamp knows the term “gentle”

Warming the casing around the tail end of the shaft
… then on the inside. Given the main case is made from aluminium the whole thing got pretty hot
With the case (by now red hot) is suspended on a couple of wooden blocks, a parallel punch is employed to drift out the idler shaft.
Reverse gear (left) and shaft (both quite hot). The bush in the gear is vey worn and will be replaced. The gear will live to fight another day…which is just as well as these simple gears are staggeringly expensive to replace