Gearbox

I have some gearbox questions
My gearbox was long overdue a overhaul
There is damage to one of the kickstart shaft retaining plates
It's sometimes hard to select first gear and generally a bit stiff to shift also the Kickstarter was moving back under hard acceleration it is already fitted with a two piece layshaft bearing
Upon striping the gearbox I found the bush in the 1st gear had moved and in the pinion and looks the worse for wear
Also the inner of the two piece layshaft bearing is no longer tight on the layshaft
I will try a new bearing on the layshaft to see if this takes up the play, if not will loctite be enough to cure this? If so which loctite?
What would cause the bush to move in the 1st gear pinion?
Also I have found the top of my maney outrigger has cracked,this is the second time it's happened now I can only assume there is some misalignment there or what else would cause it to crack?

baz said:

Upon striping the gearbox I found the bush in the 1st gear had moved and in the pinion and looks the worse for wear

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More likely the 1st gear bush has begun to break up (as they do when they are worn) .......



.....and perhaps hasn't moved as the bush extends from the gear and there's a recess in the layshaft bush to accommodate it.

Thanks Lab I see what you mean
It's so long since I've been in a Norton box I was thinking it should be flush both sides
What do you think about the inner two piece bearing not being tight on the layshaft? Cheers

baz said:

What do you think about the inner two piece bearing not being tight on the layshaft?

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Previous thread: https://www.accessnorton.com/NortonCommando/layshaft-roller-bearing.4388/

About the outrigger crack , it could mean as it suppport only the mainshaft throught its bearing , that the mainshaft had some play , so either the sleeve gear bearing is shot or mainly the sleeve gear bush are shot , do you feel any side or up and down play ? is the big bearing tight in its main case ?

marinatlas said:

About the outrigger crack , it could mean as it suppport only the mainshaft throught its bearing , that the mainshaft had some play , so either the sleeve gear bearing is shot or mainly the sleeve gear bush are shot , do you feel any side or up and down play ? is the big bearing tight in its main case ?

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Yep everything is very tight, I've checked it with the out rigger removed
When I welded it I left the weld on to add strength as it had broken before

marinatlas said:

About the outrigger crack , it could mean as it suppport only the mainshaft throught its bearing , that the mainshaft had some play , so either the sleeve gear bearing is shot or mainly the sleeve gear bush are shot , do you feel any side or up and down play ? is the big bearing tight in its main case ?

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I'm wondering if the main shaft is very slightly bent?
There appears to be no wobble but I will check with a dial guage when I get time

My gearbox also in pieces & the 1st gear layshaft bush shows similar break up, but on the opposite side of the gear. Old gears now on ~95k miles & showing signs of wear, new gears ready to go in!

Mike

Found a bit more time today to look further into my gearbox
The layshaft is worn 0.005 where it sits in the kickstart shaft so will have to be replaced along with the layshaft bush and first gear pinion bush
Cheers

baz said:

Found a bit more time today to look further into my gearbox
The layshaft is worn 0.005 where it sits in the kickstart shaft so will have to be replaced along with the layshaft bush and first gear pinion bush
Cheers

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What are you using for lube?

I have been using ep 90 for years, but recently changed to ATF only because I read it on here and the box was getting difficult to shift ,it made no difference to the shifting
But the wear was already there with the ep90 also I did once run it low on oil
Cheers

My Maney outrigger broke also. First just the bottom and then both top and bottom so I removed it a long time ago. It seemed to have just enough flex to fatigue after a few years.

I plan to install a TTI box in my bike this winter.
I will be interested in seeing how the old trans looks. It's been well over 100,000 miles since I have done anything more than kicker pawls. It still works good though.

comnoz said:

My Maney outrigger broke also. First just the bottom and then both top and bottom so I removed it a long time ago. It seemed to have just enough flex to fatigue after a few years.

I plan to install a TTI box in my bike this winter.
I will be interested in seeing how the old trans looks. It's been well over 100,000 miles since I have done anything more than kicker pawls. It still works good though.

Click to expand...

I think you are correct about the fatigue
I thought it was a great Idea when I fitted it, maybe a bit over the top for a road bike but I liked the thought of it supporting a hard pressed gearbox with more power being put through it than it was designed for
Plus a clutch hanging even further out than the box was designed for
One issue for me is I cut a hole in the Alton inner primary case to accommodate it!!
Plus the AC has packed up on my Tig plant so a repair to the outrigger will have to wait if I do decide to repair
Cheers