Almost Ready MK3, Now I'm Scared: Layshaft

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I've had the main shaft end nut come loose a couple of times to loose ability to adjust clutch, so besides tight nip up its not bad ID to add some blue loctie to this one. The ring nut is a bit of a bugger to do because ya need to get the thing final tight, while the whole gizmo wants to turn out of line with cable entry on the last couple final tapings. Its another Norton example to prove just being able to turn a wrench or use a drift don't mean you are an effective mechanic yet, ugh.

After quizzing the old original men of Norton-doom I've come to conclusion they are right to leave the gaskets out as they crush down after a while and may cause the main shaft end nut to loosen up, besides eliminate the lay shaft shim game.
 
I made a special tool to get that thing off, and didn't use it, too cumbersome. I like the punch and hammer method like Hemmings. Works a treat, it's not like it's got 800 yd/tons on it.

Dave
69S
 
i just started taking mine apart today and i used a punch and hammer and it took three light taps before it was breaking loose. Now i'm wondering because i see a few mentions here of it, should i buy the mick hemming gearbox dvd before trying this myself for the first time or will the old brits, and various other online tid bits along with a chiltons and norton manual be enough?
 
there may be a youtube on it as seen one on Amal servicing. In my timid case I was very assured I could handle it only after viewing a famous old fart I can't remember name of now, fumbled his way in and out ok. The trouble with that old VHS video and maybe the newer ones is they skip over stuck stuff issues and fine details of getting cam plate cogs indexed and finest key to the pawl spring diddling. What else is missing is how to examine shafts and such for quality to re-use. Its easy to over look a twisted shaft functioning well on the bench then wonder why sealing and bushes and sweet neutrals or clutch wobble don't stay right...
 
hobot said:
there may be a youtube on it as seen one on Amal servicing. In my timid case I was very assured I could handle it only after viewing a famous old fart I can't remember name of now, fumbled his way in and out ok. The trouble with that old VHS video and maybe the newer ones is they skip over stuck stuff issues and fine details of getting cam plate cogs indexed and finest key to the pawl spring diddling. What else is missing is how to examine shafts and such for quality to re-use. Its easy to over look a twisted shaft functioning well on the bench then wonder why sealing and bushes and sweet neutrals or clutch wobble don't stay right...
Click to expand...
no kidding, taking a break now from trying to get the main shaft nut off. Screwed the chain down to my workbench, a couple heads snapped off, and the last attempted started to pull the top off the workbench! (i admit it's not screwed down well :roll: )
 
Get that mainshaft nut off. Use a screwdriver to prise up the gear selector quadrant arm to find a gear.Soak the nut in WD40 overnight. Lock up the final drive with gear selection , brake application tied down or even a chunk of wood to stop things turning because you are going to fit the socket to the nut and strike the power bar or even ratchet hard to shock free that nut. Whew !
 
Torontonian said:
Get that mainshaft nut off. Use a screwdriver to prise up the gear selector quadrant arm to find a gear.Soak the nut in WD40 overnight. Lock up the final drive with gear selection , brake application tied down or even a chunk of wood to stop things turning because you are going to fit the socket to the nut and strike the power bar or even ratchet hard to shock free that nut. Whew !
Click to expand...
i just quit for the night....lol the bike is all the way apart, so i have the trans in it's cradle, the cradle in my vice with a ratchet strap holding it still in the vice. Then i have a 2x3 screwed to the wall into two studs, chain screwed to that, then to the work bench on the other side. Soaked it with PB blaster, heated it up, put my hand on the rear iso tube of the cradle, leaned all my weight back and almost had my ass on the floor and pulled the breaker bar...and the vice ripped the whole top off my work bench! gonna soak it overnight, then take it to my shop and try an impact on it. if all else fails i'll give it to the guy who's building my motor to deal with :shock:
 
Now that is funny. Sorry, my wife even got a kick out of that description. I can see it.

Would it be ok to use an electric impact wrench to remove the mainshaft nut?
JD
 
Thanks for your help everyone. Itp gives me confidence.
I can't wait until tomorrow to get back on it.
I measured .027" endplay in the ks shaft, is this ok? I won't be able to see the guts until tomorrow, so I don't know what's causing it.
I believe Hobot said leave off he inner gasket would tighten it up. Sounds good to me.
JD
 
I used an air impact wrench, came off easily, took 3 good shots, I expect an electric impact wrench would work too.
 
Code: 
i just quit for the night....lol the bike is all the way apart, so i have the trans in it's cradle, the cradle in my vice with a ratchet strap holding it still in the vice. Then i have a 2x3 screwed to the wall into two studs, chain screwed to that, then to the work bench on the other side.

This part almost made me stop and directly ask for photo of the Rub-berg appliance ... till next part now wishing for a video!!

oaked it with PB blaster, heated it up, put my hand on the rear iso tube of the cradle, leaned all my weight back and almost had my ass on the floor and pulled the breaker bar...and the vice ripped the whole top off my work bench!
Click to expand...

Btw if this is the counter sprocket nut, its Left H reverse threaded like propane fittings. Also Hot ain't really Norton threshold hot till like frying pan oil smoking hot. Might think about impact this time or risk buggering the flats but shouldn't normally be required. ATF works better than the lighter fluid like grease cleaner wd40. wd40 has a use in the heat freeing by cooling spray on the hot part you want to shrink.

I've torn my vice off by taking off with the under lying wood doing knee drop karate death kicks on long lever stuck in a stuck up brake caliper cap... and almost my knee cap too but finally won, but only after crying to world wide lists after days of failures >>> so their collective mind hive could change the quantum bonds of fused elements so cracks in its reality provided the relief on very next attempt. More than once, so its proven to me telekinesis is a vital part in novice Norton tool kit.
 
As far as I can recall ,the cheapo run of Portuguese bearings were fitted into 828 cc. model gearboxes. So don't know when they first started being installed. But this problem can occur in earlier higher mileage (anyone's definition) gearboxes as well. A tic - tic -tic sound and kickstart movements are your warning failure is imminent.
 
okay one crappy cellphone pic, cause i'm far too lazy to put any production into sharing my shame!
Almost Ready MK3, Now I'm Scared: Layshaft


starting to wonder why i'm working on this norton and not one of my dads other abandoned toys
Almost Ready MK3, Now I'm Scared: Layshaft
 
Nice damage ,looks like you're ready for some new furniture. Wonder where to get some... That car will pass everything on the highway but a gas station. Proceed with Norton.
 
Torontonian said:
Nice damage ,looks like you're ready for some new furniture. Wonder where to get some... That car will pass everything on the highway but a gas station. Proceed with Norton.
Click to expand...
yeah my garage is made up of the kitchen cabinets that were in the house when we bought it. Not exactly tough stuff :oops: The camaro is eco friendly, needs no gasoline, push only! Been sitting just as long as the norton.
 
Progress Report: I removed the clutch operating lever assy nut easily with a brass drift.
The mainshaft nut came off easily with my battery powered impact wrench. I didn't have to chain anything to the wall. Everything looks good and clean so far.
I had to turn down a 9/16 socket to get onto some of the 7 nuts. The rearmost outer nut brought its stud out with it.
Now the inner cover is off and the only problem I see is the mainshaft bearing feels like it is a fine rachet. Seems to be notchy as I turn it with my finger.
Should I replace it? I am surprised, this thing has been ridden gently for 14k and I don't see why it wouldn't be smooth.

Now the layshaft is staring me in the face. It wiggles a little but won't budge. Can I rig up a puller to grab a gear and pull it out?
What's next?
Thanks for the help.
JD
 
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