To rebuild or not to rebuild-dang transmission (Rebuilding)

Status
Not open for further replies.
Re: To rebuild or not to rebuild-dang transmission

Guido said:
I just did my box yesterday. New shafts and bushings. Did the roller bearing and shimming is a snap.
Had .042 endfloat, took it up with .030 of rear iso shims, done.
The bearing was about $25
Click to expand...

Guido,
I am curious why you chose to replace the shafts, did you determine they were worn or damaged?

Did you have any issues with the bushings, I have read they require reaming and that it can be tricky.
 
Re: To rebuild or not to rebuild-dang transmission

I am breaking her down. I had some chores to finish up before I could get some work done:

1. Mow Lawn...Check
2. Clean off back porch....Check
3. Fix push mower so it would self propel...Check
4. Clean up after all chores...Check
5. Get daughter and sons friends over so they all could play... Check

Ok, now my back is hurting I got down to it.

I took off the exhaust last week
To rebuild or not to rebuild-dang transmission (Rebuilding)


Here are a couple of cross over pipe bolts, one broke and one is warped..
To rebuild or not to rebuild-dang transmission (Rebuilding)


Decided to not put on cross over exhaust again, want a cleaner look.

Oil tank, and right Z Plate off...
To rebuild or not to rebuild-dang transmission (Rebuilding)



I got the primary off, clutches out and clutch sprocket nut off..
To rebuild or not to rebuild-dang transmission (Rebuilding)

To rebuild or not to rebuild-dang transmission (Rebuilding)


Going to have to loosen primary chain so I can take off clutch basket and sprocket.

Will post more when I get a chance to do some more work on it.

Maybe by next weekend, have to till out the ground where I went 4X4 with my Mustang getting it out to sell. Ruts were deep enough Mustang was sitting on ground, can see where exhaust burned ground.

Now, I need to clean up the garage, make sure I have everything bagged and tagged and clean up my nasty butt!!
 
Re: To rebuild or not to rebuild-dang transmission

T95 said:
Guido said:
I just did my box yesterday. New shafts and bushings. Did the roller bearing and shimming is a snap.
Had .042 endfloat, took it up with .030 of rear iso shims, done.
The bearing was about $25
Click to expand...

Guido,
I am curious why you chose to replace the shafts, did you determine they were worn or damaged?

Did you have any issues with the bushings, I have read they require reaming and that it can be tricky.
Click to expand...

I bought this bike, a '74, in '82 or so as a Dunstall Cafe racer. Converted it to an upright stock appearence.
I never went through the tranny on this bike, just my other bike, the '73.
This one was so worn out that I replaced the entire insides with gears from a gear box I bought on this site and replaced all the bearings and bushings.
The main shaft was badly worn so I bought a new one. The lay shaft was replaced with a good used one which mic'ed out fine and was true between the centers.
I had the first gear lay and the 4th gear sleeve bushings pressed in by Phil Radford and I did the rest. Only one bushing in the 3rd gear lay had to be reamed but since I had no reamer,
I used a brake cylinder hone to open it up.
This box had the super blend lay bearing but the previous owner did nothing to the end float so it had over .042 side play.
Now it is so tight, but not too tight, if you know what I mean.
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

Did not plan on doing anything on the bike today but am off and the morning started off kinda crappy. Decided to go out and get some more done to get my head right and found this:

To rebuild or not to rebuild-dang transmission (Rebuilding)

To rebuild or not to rebuild-dang transmission (Rebuilding)


I was actually reading some post on this (Rotor cupped washer) and low and behold I have one on my bike.

Then as I took off the outer cover and taking the internals apart I saw this:
To rebuild or not to rebuild-dang transmission (Rebuilding)


Do you see it?
How about now:
To rebuild or not to rebuild-dang transmission (Rebuilding)


It is a transmission vent, I have seen this on Old Britt's site where he does the modification on the trans inner cover. I thought these only came on the 75 models.

My engine, trans and frame plate match (317975). Does this mean someone has been in this bike before? The washer (think was called a Kingston washer) I read was put on bikes to compress the rotor on the crankshaft because they had a issue of getting loose and destroying themselves? Am I wrong on this or what.

Would appreciate some information on this from you guys.

Going to read over the rest of the tear down before I go back out and maybe get some more done today.
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

warpedscout said:
It is a transmission vent, I have seen this on Old Britt's site where he does the modification on the trans inner cover. I thought these only came on the 75 models.
Click to expand...

Apparently not, as part: "065199...Breather tube" (same number as 850 Mk3) is in the 850 Mk2/2A parts book (Group 8, Gearbox inner cover)
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

Any tricks on getting rotor off crankshaft?
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

Put a puller on it, tighten up and heat the sprocket. It will come. I used a heat gun and it popped off after about 1 minute. Not necessary to beat on it.

Dave
69S
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

warpedscout said:
Any tricks on getting rotor off crankshaft?
Click to expand...
Should slip on and off. Don't overwork it, little heat, very little tappy tap.
 
Re: To rebuild or not to rebuild-dang transmission

Niagara850 said:
Right in the middle of going through the gearbox and checking the layshaft bearing myself. Doing it in frame . So far the biggest difficulty was getting the layshaft bearing out of the case. Lots of heat and patience required. I found a standard $10 steel cage 6203 bearing that someone replaced the original Portuguese brass cage bearing with sometime during its life.

Researching the threads and the internet, it looks like there are two suitable choices for layshaft bearing replacement:

- FAG 6203 TB.P63 - a quality ball bearing with a strong phenolic cage that doesn't require shimming. Mick Hemming recommended, along with many forum members.

- NJ203E C3 Roller bearing, also a quality bearing with polymid cage that requires shimming, factory recommended, along with many forum members, see Old Britts and the Norton workshop companion for installation details. As the inner race floats, axial loads are reduced on the cage.

I took my the bearing removed from the gearbox down to the local bearing supplier - Canadian Bearing

FAG 6203 TB.P63 - $69.99 but special order that takes 6 weeks to arrive
FAG NJ203E C3 - $56.07 which I ordered - 4 days


SKB NJ203E C3 - $70.52 in stock

Not having a Dial Indicator, I would have gone with the FAG 6203 TB.P63 to save shimming but too long to receive, and I could use a Dial indicator anyway... I checked prices from various Norton parts suppliers, they can be ordered for more $. It pays to cut out one of the middle men.

Now to get the sucker back together, spring has come early this year, 18c and sunny, 20c and sunny forecast for next week, normal is 4c. We usually get a snow storm around St. Patrick's day...
Click to expand...

If you are wise you will check and shim the layshaft whether you are using a ball bearing or a roller bearing. The result of too much end play in the kicker shaft is the same with either bearing- the gearbox tends to jump out of first. Of course if it didn't jump out of first before you took it apart it isn't going to be any more likely to with a roller bearing so it's your choice but excess clearance there will eventually catch up to you. Jim
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

I'm going to properly shim it. The gearbox behaved well prior to dis-assembly, no jumping out gear, snicked into gear, finding neutral was easy. The clutch would drag when it wasn't fully warmed up, so I would slip her into neutral just before coming to a stop for the first few miles to save stalling. Cleaning clutch plates and adding clutch rod seal next on the to do list.
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

Got rotor off and calling it a night. Purchased. HUGE vise from lowes so I gotta get that on my work bench in the next few days when I get time. Gotta go out of town to do inspections so I feel very little will get done. Maybe get trans broke down this weekend and see what it links like. Thanks everyone!
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

Damn you, damn you all to the lower bowles.of hades¡ Just fer mud in yer eye I am gonna rebuild it and post really bad close ups while I talk about my literature class. That will teach ya, hahahahahaaha!
Click to expand...

I've said it before, and I'll say it again: This forum is like having a mother who is also a British Motorcycle Mechanic.
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

Ugh, not getting much done this weekend. Got the crank sprocket off tonight, need to do some bagging and clean up done tomorrow.seems like I had ask the time in the world until I started this now I don't have a spare minute. Hope to have some progress and pics up tomorrow.
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

OK, got a little done today, looks like I need to order some Whitworths, got a few nuts on the inner transmission cover I cannot get off. Still have the drive chain on the bike with my brake locked up:

To rebuild or not to rebuild-dang transmission (Rebuilding)



Hoped to have the inner cover off today but does not look like it, was ready to make some progress!

To rebuild or not to rebuild-dang transmission (Rebuilding)


Did get the Primary cover off:
To rebuild or not to rebuild-dang transmission (Rebuilding)

What do you guys use to get the chain drive sprocket nut off? Any suggestions would be appreciated!

Tell you how bad I have been out of it, we had a neighbor shoot his wife last night about three houses down across the street and did not even know it! Did not see a single light or hear any sirens and I was sitting in the living room when it happened. I need a vacation!!

Oh well, I am taking it slow and making sure to tag and bag everything, need to get to cleaning some of the parts I have taken off.

Will probably order a set of Whitworth sockets and spanners tonight, maybe next weekend I can have the tranny case off.

Have been getting my garage ready a little more, got a vise so I can do some work when I get the transmission out:

To rebuild or not to rebuild-dang transmission (Rebuilding)


Hope this thing will last for a few years (Translate to Decades)

Going to look at some flooring mats for my garage to put under the bike, currently have a painters tarp under it but want something a little easier to move the bike around on.

Any suggestions, like I said previously, would be greatly appreciated! I get into taking apart the bike and do not want to stop since my time is little I am getting to spend with it. My mistress is lonely!!

Hope everyone had a great weekend!!
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

The drive sprocket nut is close enough to 1 1/2". You can get one at Walmart in the towing section or Harbor freight has them, about $10. Or you can make up a very deep 1 1/2" socket by welding 2 deep sockets together.

Dave
69S
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

Forgot to ask, does anyone have a picture of the plywood engine stand? I read about it in the forum but the pics were gone, just need to get one done so I can get the engine out of the frame.

Thanks!
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

DogT said:
The drive sprocket nut is close enough to 1 1/2". You can get one at Walmart in the towing section or Harbor freight has them, about $10. Or you can make up a very deep 1 1/2" socket by welding 2 deep sockets together.

Dave
69S
Click to expand...
Buy two of these for 9.99 each at Autozone or Advance auto. Cut one down in a chop saw, grind chamfer on both side and throw down a bead. Stick it on the end of an electric impact and away you go. On install you can nudge with impact to get that screw just right on the retaining washer.
To rebuild or not to rebuild-dang transmission (Rebuilding)
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

warpedscout,
If you are talking about the counter-shaft sprocket nut,I got a 38mm deep impact socket,6-point,from Auto-Zone for about
$19.00 dollars.Remember that it reverse thread(LH)
YING
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

YAY, got some toys in today. Whitworth socket and spanners (Hehehe). Got the nuts off the transmission now have to get a 1 1/2 spanner to get the nut off the layshaft??

Been busy with other things today since I have been off, working on military award frames and finished them up. My mom brought me an Olde English 800 sign that was in my grandmothers old shed that is falling apart. I took it apart, cleaned it up and got it working:

Lights on
To rebuild or not to rebuild-dang transmission (Rebuilding)


Light off:

To rebuild or not to rebuild-dang transmission (Rebuilding)


Hope I get some time over the next few days to get back to the transmission and get it apart this weekend and check it out.

Did get the handlebars, battery tray and horn and a few other pieces off. Started on taking the gauges off but going to have to read through the articles on how to do that and get the forks apart.

Oh well, bed time it is. Night John Boy!
 
Re: To rebuild or not to rebuild-dang transmission (Rebuildi

You did catch that part about the chain sprocket being Left Hand threads, didn't you?
Also the inner cover nuts can be taken off with a 6 point 14mm socket if you don't have Whitworths but I see you just got some so never mind
 
Status
Not open for further replies.
Back
Top