ES2 Clutch problem

The clutch basket is held rigidly in place via the Nut, mainshaft on the nearside. If that has backed off the clutch basket will move to the extent that freeplay is allowed.

Unless the mainshaft bearings have gone duff, this is the only thing that I can think of.

Hi John,

There is a more common cause, your clutch plates (not friction plates!)are distorted. Don't panic this is not as bad as it sounds! Over time and use this does happen and the way to check for this is to put one on a perfectly flat surface and see if there is a gap between the surface and the inner rim. If there is you WILL get clutch drag and no amount of adjustment will cure it. These can be straightened but it may be easier to source replacements as they may do it again.

Hope this helps!

James

Hi John,

There is a more common cause, your clutch plates (not friction plates!)are distorted. Don't panic this is not as bad as it sounds! Over time and use this does happen and the way to check for this is to put one on a perfectly flat surface and see if there is a gap between the surface and the inner rim. If there is you WILL get clutch drag and no amount of adjustment will cure it. These can be straightened but it may be easier to source replacements as they may do it again.

Hope this helps!

James

Is it not also possible that the clutch basket is worn where the tangs of the friction plates ride in the grooves?

Mike

The clutch on my ES2 will sometimes drag if the primary chain runs too tight, this problem also occurs on my Dominator that has a belt drive fitted, when the belt tension is correct the clutch is fine.

Hi.

It sounds to me as though you definitely have too much play in your mainshaft. The end-float should be 1/32nd of an inch. On Manx upright gearboxes the mainshaft play is 8 to 10thou. This is adjusted by fitting shims (~13 thou) behind the clutch worm nut. These push the mainshaft bearing inwards so taking up any play.

The usual cause of excessive end float is wear of the bronze thrust washer between the 3rd & 4th gear. In addition to this there is a hardened steel washer between the bronze washer and the rollers in the 4th gear. The grooved side of the thrust washer goes against this. Also, there should be large pen steel washers either side of the large sleeve (4th) gear bearing (to cut down on oil leakage apparently). These are a pain and always seem to break up. There should also be a dished steel washer between the small 1st gear and its bearing â concave side to the bearing.

3/16 of an inch play is excessive â have you got all the bits? I say this because the gearbox diagram in the Norton Maintenance Manual, that I have, does not show the hardened steel washer that fits inside the sleeve gear between the rollers and the thrust washer. If it is missing it would explain the amount of play.

Cheers.

Ian.