Clutch inspection time

Portofino Norton's Garage · Jun 16, 2026

no absolutely they were perfectly fixed

cliffa · Jun 18, 2026

Portofino Norton's Garage said:
no absolutely they were perfectly fixed

This is what Greg Allen from the Facebook group did to repair his. He used a Dremel type tool to grind away the damaged material, and shape semi circular recesses then inserted woodruff keys into the basket…

Portofino Norton's Garage · Jun 18, 2026

I've found at Thiel a complete used cltuch basket but no indications about mileage and impossible to see the real wear without dismounting.
By the way do you know if the cush drive spring seats in the clutch basket are flat or rounded on the springs shape? Mine are so worn that it is not clear.

cliffa · Jun 18, 2026

Portofino Norton's Garage said:
I've found at Thiel a complete used cltuch basket but no indications about mileage and impossible to see the real wear without dismounting.
By the way do you know if the cush drive spring seats in the clutch basket are flat or rounded on the springs shape? Mine are so worn that it is not clear.

I don't think Ollie would sell a bad one.

Have a look here. https://www.accessnorton.com/NortonCommando/another-clutch-basket-failure.30698/#post-481786

Portofino Norton's Garage · Jun 18, 2026

I didn't say that, only also my clutch basket appeared perfect until dissasmbled. it is impossible to see the springs seats wear without opening the device and removing the springs.
No one can guarantee it at closed eyes.

cliffa · Jun 18, 2026

Portofino Norton's Garage said:
I didn't say that, only also my clutch basket appeared perfect until dissasmbled. it is impossible to see the springs seats wear without opening the device and removing the springs.
No one can guarantee it at closed eyes.

Agreed, however if the spring pockets are worn the basket will have rotational play, which can be discerned without dissassembly.

Portofino Norton's Garage · Jun 18, 2026

not in my case Cliffa, no rotational play neither on the rivets. And the wear inside was severe, with springs approaching an eventual failure

Stephen_Spencer · Saturday at 11:37 PM

cliffa said:
Agreed, however if the spring pockets are worn the basket will have rotational play, which can be discerned without dissassembly.

Hey Cliff, Tony et al.

This is the most recent commentary on the dreaded clutch disease, so I’ll add to this and seek a little advice if I may - I think I may have contracted it!!

I mentioned on another thread that whilst checking for clutch serviceability, I found minimal rotational play of the basket. I’ve had a closer look today (after my weetabix) and found further rotational play, independent to the basket. Shown in video clip.

It is rotational only with approx 1mm of movement. So am I right in saying that indicates likely wear to the spring pockets/springs, as opposed to worn/failing rivets? Is 1mm too much - is any movement acceptable?

Appreciate your assessment.

TonyA · Sunday at 9:10 PM

Stephen_Spencer said:
Hey Cliff, Tony et al.

This is the most recent commentary on the dreaded clutch disease, so I’ll add to this and seek a little advice if I may - I think I may have contracted it!!

I mentioned on another thread that whilst checking for clutch serviceability, I found minimal rotational play of the basket. I’ve had a closer look today (after my weetabix) and found further rotational play, independent to the basket. Shown in video clip.

It is rotational only with approx 1mm of movement. So am I right in saying that indicates likely wear to the spring pockets/springs, as opposed to worn/failing rivets? Is 1mm too much - is any movement acceptable?

Appreciate your assessment.

Hello Stephen , I don’t think it should rotate easily. Can I ask if the rotation of the basket is independent of the clutch ring gear ? I am not asking about the starter ring gear here. I have a full clutch here in the garage I can check. I want to say that the rivets should be holding the basket together relatively tight. But Stu should be asked for an opinion , he deals with many more clutches than I have.

Stephen_Spencer · 2026-06-29T01:50:50-0600

TonyA said:
Hello Stephen , I don’t think it should rotate easily. Can I ask if the rotation of the basket is independent of the clutch ring gear ? I am not asking about the starter ring gear here. I have a full clutch here in the garage I can check. I want to say that the rivets should be holding the basket together relatively tight. But Stu should be asked for an opinion , he deals with many more clutches than I have.

Hi Tony - thanks for the input. Have to admit I’m struggling a bit to fully understand the relationship between the clutch basket, clutch gear and the cush drive plate and springs - having never stripped them.

As best as I understand, the rivets hold these assemblies together axially, whilst allowing a slight rotational movement of the clutch gear (whilst the springs compress in the cush plate) before rotation of the clutch basket occurs.

The slight rotation of the clutch basket on my bike is independent of the clutch gear. Pretty sure I can hear the cush springs tapping against their housing, rather than a metallic knock that might indicate loose rivets.

I don’t know if Stuart monitors this site regularly in the same way as he does FB - much quieter on here of course. I may try and send him a DM on his Motorvated site. Certainly willing to remove the clutch and send it back to Stu for refurb if necessary.

Would it be worth removing the clutch internals to view the rivet heads, without removing the basket? I know I won’t be able to rule out loose rivets entirely, but it may provide other clues. A quick check for any movement between basket and gear on your spare clutch would be useful

.

Thanks Tony, appreciated. Steve.

TonyA · 2026-06-29T07:55:53-0600

Stephen_Spencer said:
Hi Tony - thanks for the input. Have to admit I’m struggling a bit to fully understand the relationship between the clutch basket, clutch gear and the cush drive plate and springs - having never stripped them.

As best as I understand, the rivets hold these assemblies together axially, whilst allowing a slight rotational movement of the clutch gear (whilst the springs compress in the cush plate) before rotation of the clutch basket occurs.

The slight rotation of the clutch basket on my bike is independent of the clutch gear. Pretty sure I can hear the cush springs tapping against their housing, rather than a metallic knock that might indicate loose rivets.

I don’t know if Stuart monitors this site regularly in the same way as he does FB - much quieter on here of course. I may try and send him a DM on his Motorvated site. Certainly willing to remove the clutch and send it back to Stu for refurb if necessary.

Would it be worth removing the clutch internals to view the rivet heads, without removing the basket? I know I won’t be able to rule out loose rivets entirely, but it may provide other clues. A quick check for any movement between basket and gear on your spare clutch would be useful.

Thanks Tony, appreciated. Steve.

Hello Steve , I looked at my spare clutch basket and can tell you it should be tight. My spare basket is from my 2014 November build and after more than 23,000 miles it is still tight. Those clutch parts should be sandwiched together tightly with no
play. It is possible that the rivets can be re-peened and then welded. Talk to Stu asap.

Stephen_Spencer · 2026-06-29T16:24:14-0600

TonyA said:
Hello Steve , I looked at my spare clutch basket and can tell you it should be tight. My spare basket is from my 2014 November build and after more than 23,000 miles it is still tight. Those clutch parts should be sandwiched together tightly with no
play. It is possible that the rivets can be re-peened and then welded. Talk to Stu asap.

Hi Tony, expected that to be the case. I’ll contact Stu for further advice. I’d like it sorted properly as the bikes a keeper. Ideally re-riveted/bolted, springs changed, ring gear pinned.

I suspect the rotational movement may be the result of wear to the spring pockets as Cliff points out above, but not certain of course.

I was hatching a plan to try and rule out loose rivets (as best I can) and continue riding whilst I order a new clutch - keeping a spare as you have. May be a bit too risky!

CNW no longer stock 961 tools so I’ll contact the Coote’s directly to get hold of the gear jam tool. I have the clutch jam tool.

I’ll update the thread with progress. The joys of owning a ‘hand made’ bike - part of the journey! I have other bikes to ride

.

Thanks Tony - appreciated. Steve.

TonyA · 2026-06-29T16:47:52-0600

Stephen_Spencer said:
Hi Tony, expected that to be the case. I’ll contact Stu for further advice. I’d like it sorted properly as the bikes a keeper. Ideally re-riveted/bolted, springs changed, ring gear pinned.

I suspect the rotational movement may be the result of wear to the spring pockets as Cliff points out above, but not certain of course.

I was hatching a plan to try and rule out loose rivets (as best I can) and continue riding whilst I order a new clutch - keeping a spare as you have. May be a bit too risky!

CNW no longer stock 961 tools so I’ll contact the Coote’s directly to get hold of the gear jam tool. I have the clutch jam tool.

I’ll update the thread with progress. The joys of owning a ‘hand made’ bike - part of the journey! I have other bikes to ride.

Thanks Tony - appreciated. Steve.

You should take out all the clutch springs , pressure plate , fiber and steel plates . Lock the basket and ring gear and remove the clutch nut . You can now remove the clutch center hub. Once this is off you can rotate with your hand and examine this side of rivets for loosening.

Stephen_Spencer · 2026-06-30T00:57:09-0600

TonyA said:
You should take out all the clutch springs , pressure plate , fiber and steel plates . Lock the basket and ring gear and remove the clutch nut . You can now remove the clutch center hub. Once this is off you can rotate with your hand and examine this side of rivets for loosening.

Just about to do that thanks Tony - should help me make a better assessment.

Contacted Richard Coote for a Gear Jam Tool and just about to contact Norton for a quote on a new clutch.

Don’t think there sre any compatability issues with a Solihull clutch - unless anyone knows different?

TonyA · 2026-06-30T06:56:43-0600

Stephen_Spencer said:
Just about to do that thanks Tony - should help me make a better assessment.

Contacted Richard Coote for a Gear Jam Tool and just about to contact Norton for a quote on a new clutch.

Don’t think there sre any compatability issues with a Solihull clutch - unless anyone knows different?

Compatibility issues ? I am running a 2023 clutch basket now on my November 2014 build . They look exactly the same.

TonyA · 2026-06-30T07:08:27-0600

TonyA said:
Compatibility issues ? I am running a 2023 clutch basket now on my November 2014 build . They look exactly the same.

Can you actually get a new TVS Norton 961 clutch nowadays ? What seems difficult to understand is why you can’t buy a new clutch basket from a Norton dealer.

TonyA · 2026-06-30T07:47:59-0600

Stephen_Spencer said:
Just about to do that thanks Tony - should help me make a better assessment.

Contacted Richard Coote for a Gear Jam Tool and just about to contact Norton for a quote on a new clutch.

Don’t think there sre any compatability issues with a Solihull clutch - unless anyone knows different?

EBC makes a Norton 961 clutch holding tool. They are available on EBay or direct from UK.

cliffa · 2026-06-30T08:25:06-0600

Steve, you definitely need to investigate further as there shouldn’t be that kind of play. My suspicion is that the pockets for the cush drive spring are worn. Once you have the clutch off you will need to drill out the rivets in order to get a better picture.

Clutch inspection time

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