A customer drew my attention to this thread, so allow me to comment.
1. The bearing cannot be flush with the sleeve gear because the sleeve has a flat that stands proud from the teeth of the gear- see your 6th picture from the top where this shoulder can be clearly seen.
No matter what the radius is on the inner race of the bearing the shoulder will still stop against that flat and daylight will be seen.
I took a new sleeve gear out of my stock. The shoulder is at 90° to the shaft of the gear with no perceivable radius, so whether the sleeve gear bearing has a radius or not- and our current ones have- should make no difference when fitting the bearing to the sleeve gear. Our bearings are not ground by us, we buy them as they are.
You tried to fit that bearing to a used sleeve gear of unknown origin. The problem may come from the bearing- I doubt it, having personally rebuilt two gearboxes with our bearings for my own bikes in the last twelve months-
or from the used sleeve gear.
Two trade customers of mine, both very experienced and competent, repair and restore one Norton after the other. If parts are lacking in quality I hear back from them very quickly. I have not heard from them about gearbox mainshafts or sleeve gear bearings for many years- indeed can't remember if we ever had problems with the mainshafts, before or during my now 8-year reign or before, and certainly never about sleeve gear bearings.
2. I next took a new mainshaft and second gear out of stock. I slid the gear on the mainshaft. No stoning by hand necessary, just slide on and off in whatever direction.... sorry! Our current mainshafts look nothing like the shaft your photo shows. What was the Andover Norton address on the package? Andover, Hungerford, or Southampton? I just wonder how old the shaft in question was.
3.
AN must have sold you "export quality" material since you are too far away from them come over and grab them by their necks.
An old saga, and a practise I actually experienced with certain British "Norton Specialists" in years gone by. But not ours. We have introduced a quality control system after I took the company over, against considerable internal resistence from old hands. As every manufacturer can confirm there is always the odd mistake slipping through. But we try.
If you have quality problems with our parts,
WE like to hear about them. It may be a real problem, say a manufacturing fault we did not recognize at the goods inward check. With quality issues more often than not the goods aren't ours but the customer
thought they were ours because misleading imitations of our labels by the seller led him to that conclusion.
Rest asured my kids and I all ride Nortons on road and track and, therefore, want our parts to be right.
I also run a 50/50 retail and wholesale shop in Germany, so get feedback on our parts every day from amateurs and professionals, and quite independently from our operation in Andover.
If you have problems with our parts, send me a pm or turn to our office in Andover,
office@andover-norton.co.uk
Joe Seifert/Andover Norton