Electra Kick Shaft splines gone

I think you have to take the inner cover off but it’s not hard, the only thing to watch is making sure the selector ratchet is correctly lined up when you put it back, there’s a recent thread on it here. I’d be prepared to replace the pawl while you are in there, the club has them. You can also do the seals if they leak at all.

Dan 

Hi Trevor,

You do have to take the inner cover off as Dan says. With care you can keep the layshaft and camplate/gearchange shaft in their plain bearings at the back of the gearbox. The trick is to not extract them with the gearbox inner cover. 

Assembly of the gearbox becomes a whole lot harder if the layshaft, and gearchange shaft come out with the gearbox inner plate. Withdraw the inner plate slowly pushing the kickstart shaft and gearchange shaft back in, as you go.

If everything does come apart, be sure to fit the 4th gear layshaft gear with gear end against the back of the gearbox. If reversed, the gear has only 50% engagement with the sleeve gear and will wear out quickly or strip teeth when engaging first gear on a sticky clutch. 4th gear layshaft gear for Electra and later lightweights is absolutely unobtainable these days.

Good luck

Peter

If, when removing the inner cover, all the gears fall out - don't despair.

It all fits only one way round - except (I think) for two items:

1) Item 15, Layshaft 4th gear. As Peter states above, its important to fit it the way shown - gear teeth against the back wall.

2) Item 29, Actuating plate. It is stamped 'OUT' on one face, you place it with the word 'OUT' facing you.

Note - Item 34, Distance piece. It is shown the wrong way round in the factory drawing.

Do you have The Electra Maintenance Manual, or the Norton Twins Manual?

All the information you need to replace the shaft is there.

Good luck!

That will help, it certainly helped me get mine back together!