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#262789 - 07/04/09 4:22 am Help needed - laydown gearbox rebuild Info  
Joined: Feb 2009
Posts: 13
hookmeister Offline
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hookmeister  Offline
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Joined: Feb 2009
Posts: 13
Melbourne, Australia
Hi,

My kick start return spring has given up the ghost so I want to use the opportunity to rebuild the box. Can anyone out there help me with where I could obtain a strip & rebuild manual??

Is there anything I should be looking out for during the process??

thanks


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#262805 - 07/04/09 9:50 am Re: Help needed - laydown gearbox rebuild Info [Re: hookmeister]  
Joined: Aug 2001
Posts: 1,923
Rohan Online content
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Rohan  Online Content
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Joined: Aug 2001
Posts: 1,923
Oztralia
The kickstart spring can be replaced without opening the box - just remove the tin cover on the kickstarter and change it. Getting the tin cover off can sometimes be an adventure...

Someone like Modak in Melbourne could possibly supply a kit of bearings and bits for an overhaul. The brass thrust washer is the important bit, it controls and sets the all important mainshaft endfloat. Inspect the gear teeth for pitting and wear - finding replacements can be an adventure too although they are around. The gear indexing plunger should be a pointy shaped thingy on top of the spring, if the pointy bit is not pointy then restore the point. Changing the bronze bushes in the case restores the gearchange action and is quite a finicky business.

There are Norton specialists around, getting a box rebuilt is not a vast expense and they know everything to look for - and buying bits in larger quantities can reduce the cost considerably, bearings particularly. Never pay the quoted price for bearings from a bearing shop, the word is discount discount discount...

Opethiselps.

#262807 - 07/04/09 9:57 am Re: Help needed - laydown gearbox rebuild Info [Re: Rohan]  
Joined: Aug 2001
Posts: 1,923
Rohan Online content
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Rohan  Online Content
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Joined: Aug 2001
Posts: 1,923
Oztralia
I should have added these are a reasonably plain box to work on, if you note carefully where everything comes from as you take it apart then it is probably one of the easiest boxes ever to put back together, without ever seeing a manual. If it looks worn or sloppy, it is....

The repair manuals are notably lacking in written detail. The Motorcycle (magazine) or similar has written a few versions which are helpful.

#262906 - 07/05/09 1:15 am Re: Help needed - laydown gearbox rebuild Info [Re: Rohan]  
Joined: Feb 2009
Posts: 13
hookmeister Offline
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hookmeister  Offline
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Posts: 13
Melbourne, Australia
I'm keen to do the rebuild myself just because I'm expecting the bike to be with me for many years and having an understanding of the workings allows me to better judge how I get home when it stands me on the side of the road (Id be naive if I thought it wont)

Chances are that I'll at some time run a Triumph conical rear hub without cush drive in the hub. If I do I'll probably run a belt drive primary to soften the system up but from what I read I'm told the gearbox will cop a hard time. What's likely to suffer /break if I go down this path?? Is ther any other ways to get cush into the system??

Rohan, thanks for the rebuild advice. The fact you mentioned Modak leads me to think you may reside in the glorious southern state of "Oztralia" as well?? Are you a member of any local MC clubs? any that you'd recommend?


'56 Dominator 99 "mid life crisis'
#262959 - 07/05/09 10:06 am Re: Help needed - laydown gearbox rebuild Info [Re: hookmeister]  
Joined: Aug 2001
Posts: 1,923
Rohan Online content
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Rohan  Online Content
BritBike Forum member

Joined: Aug 2001
Posts: 1,923
Oztralia
Fair enough. I've had a box reconditioned and then had a look inside to see how it looked - and that the tricky bits had indeed been done.

Modak offer a good telephone mail order service - I'm well north of there - they mostly have a fair range of bits, although these days that seems to depend on supply.

I've heard there is a Norton group around Melbourne with regular (monthly ?) rides.


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