961 gearbox

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Well so far I have discovered that
it was a Sportster 5 speed box
it is nothing like a Sportster box
it was a Baker Sportster box but a Sportster box won't fit
it is a box made in Taiwan that looks remarkably like a HD box but is totally different
 

MAK

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Did Thor motorcycles design an intermediate gear that did away with the backlash spring arrangement and use a sort of Cush drive arrangement.
I remember him mentioning it when I managed to get through.
Not sure if they offer a conversation at a price.
Could someone local check it out.
What is involved and how much?
 

cliffa

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On the FB 961 page , there is a guy Greg Allen (maybe he's on here as well ?) who's clutch rivets have let go on his early bike with direct gear lever. He has posted a pic of his primary internals. No sign of any Baker markings. In fact as far as I can see externally it's the same as later bikes, so presumably Norton just changed the selector drum for the later setup ?

1624640369002.jpeg
 

kinghottinger

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Very informative thread. I'm especially interested as I have an early build gearbox which needs work. On mine, the mainshaft has play in the endplate bearing.
 

cliffa

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Welcome kinghottinger !!

Do you mean the one behind the clutch? I have an early (2011) bike as well and currently have the primary off to take a look and try to find the cause of the clatter when it's warm. On first inspection it all looks fine i.e. ring gear & clutch basket tight and no bits lying in the bottom. What are the symptoms of that bearing failure ?

Cheers,

cliffa.
 

kinghottinger

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Welcome kinghottinger !!
Do you mean the one behind the clutch? I have an early (2011) bike as well and currently have the primary off to take a look and try to find the cause of the clatter when it's warm. On first inspection it all looks fine i.e. ring gear & clutch basket tight and no bits lying in the bottom. What are the symptoms of that bearing failure ?
Hello Cliffa - Yes. My mainshaft has visible play, with clutch off and being wiggled by hand. Symptoms were noisy clutch then could not engage gear (at the MOT).
 

cliffa

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Hello Cliffa - Yes. My mainshaft has visible play, with clutch off and being wiggled by hand. Symptoms were noisy clutch then could not engage gear (at the MOT).
If you have the clutch off you may want to have a look at these threads..



The 4 rivets holding the clutch basket on have been known to fail and also the screws which hold the starter ring gear.

If you use FaceBook, join Stu Bodycote's group then scroll down and you will see a basket which has an alarming amount of play caused by rivet failure.

 

kinghottinger

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Thanks. Some good info in the clutch thread you link.
PS: If anyone knows someone in the UK that could rebuild mine, PM me.
 
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If you have the clutch off you may want to have a look at these threads..



The 4 rivets holding the clutch basket on have been known to fail and also the screws which hold the starter ring gear.

If you use FaceBook, join Stu Bodycote's group then scroll down and you will see a basket which has an alarming amount of play caused by rivet failure.

Oooh not my group mate....I just loiter around there alot haha. The groups owner is Michael Cooper.
 
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Hello Cliffa - Yes. My mainshaft has visible play, with clutch off and being wiggled by hand. Symptoms were noisy clutch then could not engage gear (at the MOT).
Can you explain the play/wiggle ? Radial (up and down) or Axial (left and right) ? Is it possible that your gear selector shaft is not centered on its mounting ? What that means is you won't get full throw in one direction , up or down. Richard-7 posted a manual describing the alignment which involves centering the mechanism before tightening down.
 

kinghottinger

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Thanks for the input. As I remember, it was up down - not visible so much as audible/feelable clunking play. I'll go look for this gear selector alignment manual. (I believe I should register with the shop in the US that kindly hosts them).
If the solution is something other than replacing the main shaft and end plate, that would be good.
 
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Thanks for the input. As I remember, it was up down - not visible so much as audible/feelable clunking play. I'll go look for this gear selector alignment manual. (I believe I should register with the shop in the US that kindly hosts them).
If the solution is something other than replacing the main shaft and end plate, that would be good.
You can search this site that picture has been posted. use my name to help find it.
 

cliffa

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I think kinghottinger is referring to the gearbox mainshaft not the selector shaft Tony. Although the latter may be the reason for the poor selection, I don't think you should be feeling any play in that mainshaft bearing.
 
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