Gearbox adjuster spacer? Z plate washers? PICS!

Good day fellas,

I'm finally assembling my commando and I came across a couple things (amongst many :roll: ) that weren't too specific in the manual. Figured I'd ask the vets...

1. The gearbox adjuster bolt requires a spacer but the spacer I got does not sit flush with the cradle. Unless I misplaced my spacer and this is supposed to be a washer on the bolt side. Is the proper spacer supposed to sit flush with the cradle?


2. Also not in the manual is the diagram for the z-plates. Are there supposed to be washers on the bolt side and nut side? When I disassembled my bike I found that it only had washers on both sides of the spacer between the z plate and the frame. I've found pics of zplates online with washers but am not sure. Can you guys clear this up?


Thanks!

As far as the z plates are concerned there should be washers beneath the head of the bolt and the nut, this is good engineering practice anyway, if you miss the washer under the bolt head you will stand a chance of damaging the z plate.
Sorry, cannot help re the gearbox.

The gearbox spacer looks a bit odd as the outer diameter should match the gearbox shell casting in that area.

I believe that in addition to washers under the bolt head and nut, some have put select thickness washers between the Z plates and frame in order to get clearance for muffler and kickstart lever swing.

Is this the space you speak of? About 1/8" marked with the yellow dot. This is on the drive side between the shell and the cradle.
#34 http://www.oldbritts.com/1973_g7.html

The round nut on the outside of the cradle has no washer but is machined to travel in the adjustment groove and also keeps it from spinning.
#35 http://www.oldbritts.com/1973_g7.html

http://www.rgmnorton.co.uk/buy/9-16-gea ... r_4219.htm

30023
Andover Norton

9/16" GEARBOX TOP BOLT SPACER

OUTSIDE DIAMETER: 1 1/8" (28.5MM)
INSIDE DIAMETER: 9/16" (15.6MM)
THICKNESS: 1/8" (3MM)

Click to expand...

pete.v said:

Is this the space you speak of? About 1/8" marked with the yellow dot. This is on the drive side between the shell and the cradle.
#34 http://www.oldbritts.com/1973_g7.html

The round nut on the outside of the cradle has no washer but is machined to travel in the adjustment groove and also keeps it from spinning.
#35 http://www.oldbritts.com/1973_g7.html

Click to expand...

Pete,

thank you! also another member mentioned that the "spacer" in my pic is too small. I'll look through some boxes to try and find the spacer. That must be a washer for the bolt side.

peter12 said:

As far as the z plates are concerned there should be washers beneath the head of the bolt and the nut, this is good engineering practice anyway, if you miss the washer under the bolt head you will stand a chance of damaging the z plate.
Sorry, cannot help re the gearbox.

Click to expand...

Right! that's what I thought anyway it's just when I took it apart there weren't any washers on the bolt side and the nut side. I've googled some pics and most z plates have washers under the bolt and presumably under the nut. Thanks again!

383wss said:

Pete,

thank you! also another member mentioned that the "spacer" in my pic is too small. I'll look through some boxes to try and find the spacer. That must be a washer for the bolt side.

Click to expand...

Although the book show no washer at the bolt head, I have one on mine to separate it from the adjuster.

As far as the space goes, if it appears to be a washer, then it's not the spacer, if you catch my drift.

and just a note, yes that spacer between the gearbox and left frame IS a tight fit as it is designed to be snuggish, you have to lever a bit with a screwdriver or something to get enough clearance to drop it in there

According to the "Commando Service Notes" published by the Norton Owners Club, the Parts Book isn't correct because there should also be a 3/8 inch diameter washer that goes along with each 3/8 inch diameter spacer. The reason for this extra washer is so that the Z plates will splay outwards at the rear. This gives a little more clearance for the brake cable so that it will not hit the stud of one of the rubber exhaust mounts.

When I removed the Z plates on my bike, sure enough there were extra washers along with the spacers and I believe this was the original way my bike was put together. The 3/8 inch diameter bolts are only 2 inches long which really isn't long enough and I didn't have full thread engagement on the nuts. Also you might not be able to use a washer under the nut where the oil hose clip goes. I ended up using longer bolts on my bike.

Even though the Z plates are now splayed with those extra washers, I would move the swing arm up with the shocks disconnected to full travel to ensure that the brake cable does not hit the exhaust mount stud. You may have to shorten the stud and then use a thin hex nut instead.


Peter Joe

I would think that adding washers to move the Z-plate out on the RIGHT side of the bike would exacerbate the problem with the kickstarter hitting the muffler.