Shop suggestions for Layshaft bearing replacement

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If you really want to build your confidence up then I would suggest getting a copy of the Mick Hemmings Norton Gearbox servicing DVD. Watch it over a couple of times.
INOA has them. Good entertainment
Cheers,
Thomas
CNN
 
Doing a gear box rebuild right now. Have the Hemmings dvd in a little portable player on the work bench. Watch a little dvd, hit pause, do what Mick did. This is my second gear box this way. Also, did an engine the same way with his engine rebuild dvd.
 
+1 That how I did it, in the bike, followed the instructions. Used a heat gun in an unheated garage during winter. You have to heat the crap out of it . Jury rigged the gun for hands free and had a couple beers. It took a good 45 minutes to get it warm enough and it pulled out like a stubborn tooth. Its easy to heat the casing up when its out. Put in a C3 roller bearing with a little shimming at kick shaft end.

Shifts nicely after 1500 miles
 
I ordered the parts this morning. I'll post a follow up when thet get here and I get into it. I'm pulling the tins off this weekend to send out for paint.

I'm going w the Hemmings recommended FAG bearing. Looks like the PO had it apart once already based on all the sealant oozing out of the joints. He assured me he never replaced the bearing. Just the kick start pawl. I hope I can get the outer and inner covers off.
 
Covers off is a piece of cake ,check pawl for crushing where it engages. The best hardened ones have an "M" stamped on the side. I vote for roller but nothing wrong with ball type of higher quality manufacture. Get at it.
 
Tore into the gearbox and found the dreaded Portuguese layshaft bearing. Upgraded bearing on the way!!! Everything looks pristine except for the kick start pawl, which was getting replaced anyway.
 
Heat gun to the back of the case for 10 min and the layshaft Assy came out. Levered the old bearing off right away.
Chilled the shaft (set outside for 1 hr) then heated the new brg to 250 deg F in the oven. Went right back together.
Now to clean out the case and remove the old gaskets/ sealer before re-assembly this weekend. Hopefully my gaskets and seals will make it from Old Britts. Although I do want to thoroughly clean / polish everything as it goes back together.

Interestingly my old bearing is marked "FAG 6203 AP". No Portugal, although the bearing is most definitely shot it feels like it has sand in it. I believe my bike has about 18k miles on it and the PO who got it fairly new never changed the bearing the ball cage was intact but it looks burnt/ discolored.
 
Make sure to check your kickstart shaft carefully where the pawl cutout is located. Mine was broken (cracked) when I rebuilt my gearbox.
 
Why don't you join the Delaware Vally Norton Owners? I know there's a bunch of people in that club that works on their own bikes all the time. I'm sure they will be more than willing to help.

http://www.dvnr.org/
 
baldy said:
Make sure to check your kickstart shaft carefully where the pawl cutout is located. Mine was broken (cracked) when I rebuilt my gearbox.
Click to expand...

Mine as well.
 
hankmarx said:
baldy said:
Make sure to check your kickstart shaft carefully where the pawl cutout is located. Mine was broken (cracked) when I rebuilt my gearbox.
Click to expand...

Mine as well.
Click to expand...
Me three..
Shop suggestions for Layshaft bearing replacement


Shop suggestions for Layshaft bearing replacement
 
Mines not cracked but there is a cracked one in the box of spares that came with the bike.

Interestingly the outer cover is cracked by the top right screw hole and was epoxied from the inside.
 
Well it's all back together. It wasn't nearly as bad as I feared.
Thanks all for the help, pointers and encouragement!
 
So I finally got all my parts and was putting my gearbox back together. The new roller bearing went in smooth, and everything seemed to be going back togehter just fine. I checked the play on the kickstart shaft and shimmed it appropriately. Then, I went to put the kickstart shaft spring in place and got this. It's at least 1/8 inch away from fitting in to the hole! Any thoughts?

Shop suggestions for Layshaft bearing replacement
 
You are trying to fit in the hole in the shaft first and then pull over the peg second?
Fit the spring in shaft hole first. You may have to turn the shaft to get it to go in. Make a loop out of a cable tie. Put this around the hook on the other end of the spring. Use the loop as a handle to pull the spring hook onto the peg. Then cut the zip tie away. Lot easier than using a screw driver to try to pry the spring around. Just did one yesterday, easy peasy.
 
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