Kickstart problems

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speirmoor

speirmoor

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So this morning I'm setting out for a 100 mi jaunt in the country or so I thought.The bike refuses to start.Im kicking and kicking and notice once in a while the kickstart is slipping what feels like a notch or something.Then on the last kick something gives way because now its not engaging with whatever its supposed to.I can push the kickstart with my hand and just it feels like a ratchet or something.I guess I was lucky it happened at home and not 50mi away where I planned to have lunch.I looked at the diagrams on Old Brits website but havent figured what the lever is attached to.Could someone have an idea what happening?
 
Classic ratchet failure I've had exact same scenario occur. Open up outer cover and have at it. Usually just the little ragchet gacget and not too bad a job, if that's all it is. Possible but unlikely inside cog teeth boogered but easy to see while accessing the ratchet.
 
speirmoor said:
So this morning I'm setting out for a 100 mi jaunt in the country or so I thought.The bike refuses to start.Im kicking and kicking and notice once in a while the kickstart is slipping what feels like a notch or something.Then on the last kick something gives way because now its not engaging with whatever its supposed to.I can push the kickstart with my hand and just it feels like a ratchet or something.I guess I was lucky it happened at home and not 50mi away where I planned to have lunch.I looked at the diagrams on Old Brits website but havent figured what the lever is attached to.Could someone have an idea what happening?
Click to expand...

Almost certainly the kickstart pawl.

-Eric
 
I'm with Eric here
Kickstart Pawl Part # 062015 You will need also a Gasket set +oil. While your in there change out the Layshaft bearing with a Superblend style NJ203-C3. you will need to open up the Gearbox Inner Cover Assembly... witworth tools are needed and a good read of the Shop Manual.
Best of Luck.
CNN
 
Don't forget you can always give her a run, jump on, put her in second and pop the clutch to get her going. I had to do that on my 70 that I bought new in London. Seems there may have been a batch of soft starter pawls back then. I put up with it through Europe then back in the states from New York to Houston. There I managed to find a new pawl which I installed at a friends house. Then I was off to Los Angeles with her all back to normal. I have never been stranded on any Norton I have owned and I have had four over the years. Ride on.
 
Ive bumped started a few like that before so I guess It wouldn't have been so catastrophic.Looking at the Old Brits exploded view I see now that all is not on one page but you have to look at two different diagrams to see the relationship between the parts. There has been plenty written about the layshaft bearing and now is my opportune time I guess to take a look and see whats in there. From what Ive read all can be done without removing the gearbox from the machine? Or at least I hope so...
 
The layshaft bearing may be difficult to get out with the GB in situ. I heated my GB inner case removed from the bike and I still had to use a made up puller to get that bearing out. I did another and I had the same issue. I suppose it could be done though. You might want to pull off the primary while you're at it so you can get to everything and check the main shaft bushings.

Dave
69S
 
Yep once Im in there I'll take take care of whatever I can.I have Mick Hemmings video on order to guide me through on what to expect.The gearbox scares me in fairness as I've never opened one up before so bear with me as Im sure I'll have lots of questions.
 
Ok I'm delving in to it slowly.I have exhausted my socket range and will need to order some bigger ones.What is the size of the nut in the picture.The one holding in the bearing?
Kickstart problems

I'm also looking in to the electric start and upgrading to 3ph stator on the primary side.What is the size of the nut holding on the rotor?
Kickstart problems
 
I'll be "joining" you on this one. Although my gearbox seems to be just fine, I've decided to disassmble to generally check it out and replace the layshaft bearing and anything else that may need it. I also plan to do it in place, without removing the gearbox from the frame. I will be pulling the primary as well as I will be replacing the 530 chain/sprockets with an Oring chain. So we can compare progress...or lack of it! :)
 
Hope you don't plan to change out the 530 chain with a 530 o ring chain.....won't fit. Are you doing a 520 or 525 conversion?
 
520 oring - trying to decide whether to buy the CNW kit or the OldBritts individual parts to do the same thing. I have great regard for both CNW and OB and have purchased parts from both. Ordering the CNW kit is handier in that all parts are supplied in the kit with one part number. OTOH, In this case, the total for the OB parts ends up being a bit over 100USD less expensive. BUT...since it will be a Xmas present, the price doesn't really matter: I'm not paying for it anyway! :)
 
haha, don't know if you get this with the oldbritts, but the cnw kit includes a spacer to put behind the sprocket. Little extra insurance so it doesn't eat up your case.
 
Cool, How far have you got Mike?
I have photos taken so far and will post a blow by blow account of the layshaft bearing replacement once complete. I have reached this stage with Mick Hemmings DVD , a set of Metrinch tools and a whole lot of info from this Forum. If all goes well hopefully everyone will be able to understand and accomplish this task.
 
Starting today on the gearbox disassembly but, unfortunately, won't actually be putting the gearbox (and 520 chain conversion) back together until after Christmas. So in reality you will be done long before me! I don't have the Hemmings DVD but I do have the service manual and will refer to the OB technical section on the gearbox as well as posts here re spun bearings/locking them in place if necessary. I have a lot of experience with rebuilding car manual and automatic trannys but I've never personally seen the inside of a Norton gearbox! ;)

I'm trying to decide whether to just replace all the bearings/bushings regardless of condition or whether to just replace parts that are worn. I feel that since it's open, I should use all new bearings/bushings but that may be just wasting money.
 
I'm trying to decide whether to just replace all the bearings/bushings regardless of condition or whether to just replace parts that are worn. I feel that since it's open, I should use all new bearings/bushings but that may be just wasting money.
Click to expand...

That just depends on the value of peace of mind!! :wink:
 
I too am headed into the gearbox. It runs fine now but all I have read on the layshaft bearing going is causing me to go in. I have a 73 850 that I just recently changed out the wheel bearings for sealed ones and the original wheel bearings were made in Portugal so it seems likely that my layshaft bearing has the same origin. I have a couple of questions:

If I am a reasonable mechanic but never been in the Norton gearbox, should I try to get Hemmings DVD or is the manual and Old Britts online stuff enough?

I am changing out the pawl and all bearings, bushings, clips and seals in the tranny but is there anything else I should not pass up doing on the primary side or in the tranny area since I'm in there?
 
I just disassembled/inspected mine this morning and, IMO, the service manual and the OB tech articles are all you need. I did mine in place, unlike per Old Britts but it wasn't at all difficult. Of course, you have to remove the primary side completely as well before you can completely remove all the gearbox internals.
 
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