The clutch cable nipple broke inside the gearbox.

akira shimomura

akira shimomura

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Apr 25, 2024
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The clutch cable snapped near the nipple inside the gearbox, leaving the broken nipple lodged at the bottom of the outer cover. The repair shop says it's fine to keep driving like this, but I'm worried this nipple might cause trouble. However, considering the shape of the outer cover, I do agree with the repair shop that the nipple is unlikely to cause issues. To remove the remaining nipple myself, I need to take off the outer cover. Is there anything I should be especially careful about when removing it?
 
akira shimomura said:
The clutch cable snapped near the nipple inside the gearbox, leaving the broken nipple lodged at the bottom of the outer cover. The repair shop says it's fine to keep driving like this, but I'm worried this nipple might cause trouble. However, considering the shape of the outer cover, I do agree with the repair shop that the nipple is unlikely to cause issues. To remove the remaining nipple myself, I need to take off the outer cover. Is there anything I should be especially careful about when removing it?
Click to expand...
If just taking it off and putting it back on, get a gasket first. The only fiddly part of putting it back on is getting the gearchange shaft in the gearchange knuckle.

The round shiny part:

The clutch cable nipple broke inside the gearbox.

into:

The clutch cable nipple broke inside the gearbox.


It's not hard just fiddly. A thin long screwdriver can help.
 
Lack of confidence can make things more difficult. Norton Commandos are not rocket science. Some people learn in school, and others learn by doing. In my life I did the two ways simultaneously. Do things slowly and think about what you are doing.
 
The cover is a bear to put on, keep the gasket in place and connect up with the gearchange. To make it easier, get a wooden dowel that is a push fit in the bolt holes that keep the cover on. Cut the dowel into 2 inch lengths (5 cm?) Remove the cover, get the broken part out, clean up any dirt inside, and push a dowel into each bolt hole. Cover the outer side of the gasket with liquid gasket, hang the gasket on the dowels and carefully connect everything in place, see service manual. Bright light and steady hand essential. When all the internals are in place, pull one dowel out at a time and insert bolt. Allen head bolts are available that don't strip out like the stock Phillips heads
 
nortonmargie said:
Allen head bolts are available that don't strip out like the stock Phillips heads
Click to expand...
The outer cover screws should be slotted also any cross head screws on a Commando should be Posidriv not Phillips.
andover-norton.co.uk

Andover Norton - GEARBOX OUTER COVER SCREW KIT (ALL COMMANDOS) 7 pieces - 06.7310

GEARBOX OUTER COVER SCREW KIT (ALL COMMANDOS) 7 pieces
andover-norton.co.uk

The Difference Between Phillips & Posidriv | Screws

One of the most common questions we receive about screw heads is the differences between Phillips & Posidrive. Find out here.
www.bolts.co.uk www.bolts.co.uk
 
cliffa said:
Have you considered using a small magnetic probe through the cover? I would definitely try that first.View attachment 122073
Click to expand...
Would be helpful, but I lightly grease the knuckle so it is unlikely to move and put it in position. Then I look as I use a thin screwdriver to lift the shaft into alignment and push the cover on. I've done it so many times, that it takes seconds.

What I should have mentioned before is that if gasket sealer was used on the gasket then the hard part is getting the gasket off both surfaces.

Also, the trick @nortonmargie uses is a good one to keep the gasket in place while putting the cover on. I generally just use a dot of grease at the two dowels but her idea is better. However, I never use gasket sealer there or on the timing cover.
 
Thanks for Posidrive info. I have had Allen heads for very long time (and like the Allen heads, the bike is not original, one more bit of non-originality won't hurt) and remembered Phillips heads as what I replaced. Who knows what clueless prior owners came up with.
 
I've had luck with standard 'paper' cover gaskets (clutch, primary drive, stator, cylinder head cover) on my various bikes by using Hondabond/Yamabond - similar like Permatex ultra gray are probably OK). I just prefer the Hondabond, never lets me down. I just put on the cover's side, and wipe a bit of grease on the other. Later on they lift right off and can usually be re-installed with no hassles. I have had zero problems on the Norton gaskets doing this. All my leaks are elsewhere!
 
The first thing I would do is take the small cover off the gearbox, and drain the oil out of it. Then put piece of carpet on the floor and tip the bike upside-down.
 
acotrel said:
The first thing I would do is take the small cover off the gearbox, and drain the oil out of it. Then put piece of carpet on the floor and tip the bike upside-down.
Click to expand...
Careful! The OP might not realise you're joking!
 
cliffa said:
Have you considered using a small magnetic probe through the cover? I would definitely try that first.View attachment 122073
Click to expand...
I bought a boroscope about a 4 or5 inch screen, it is very helpful, has a knob to allow camera end to move around and a side camera, I'd use the camera and some bent up device with something on the end for grease to have a go first 😁
 
I agree with your shop advisor...the nipple loose in the outrler compartment will not cause harm...no where for it to go except down to the bottom. An oil drain out and inspecrion through the inspection plate opening should let you see/remove it with either a magnetic or a claw type pickup gizmo.
 

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