Cyclone & Endplate???

[soulsurfer]

After stripping down my motor for a complete rebuild the casing has been dipped & powder coated and new bearings fitted. I'm now fitting the Cyclone gearbox along with a new layshaft. All going well until fitting the previously fitted end plate with the cluster fitted, when its tighter than a tight thing and locks up the gearbox solid, almost as if its the wrong endplate I've now tried two more endplates experiencing the same issue, am I missing something

[joespeed]

go back to base ,fit the cluster on its own with the end plate,all ok go back fit gears with no shim on the top fit end plate again,all ok go back fit thin shim till you get it right!

[soulsurfer]

go back to base ,fit the cluster on its own with the end plate,all ok go back fit gears with no shim on the top fit end plate again,all ok go back fit thin shim till you get it right!

I've tried that, but it's as if the centres are off, with the cluster and loose gears being closed and squashed together, the endplate won't seat fully before becoming too tight

[wack 63]

Try just the layshaft and endplate,if that goes tight then suspect the rear hub bearing either being too tall or not seated correctly.

[soulsurfer]

Try just the layshaft and endplate,if that goes tight then suspect the rear hub bearing either being too tall or not seated correctly.

I tried that too, with layshaft and cluster in situ, no problem, it's only when the loose gears and cluster are fitted together that it all binds up

[wack 63]

Next job is to try the cluster and 4th gear,then 3rd then 2nd etc to see if these all turn individually ,just to rule out a tooth missmatch(unlikely but you never can be sure)Time consuming I know but you have to rule everything out,also check the gears sit slightly higher than the layshaft when fitted and not lower.

[soulsurfer]

Next job is to try the cluster and 4th gear,then 3rd then 2nd etc to see if these all turn individually ,just to rule out a tooth missmatch(unlikely but you never can be sure)Time consuming I know but you have to rule everything out,also check the gears sit slightly higher than the layshaft when fitted and not lower.

I've had the endplate on and off so many times now, I can do this in next to no time Sounds like the next logical step, thanks

[Tom Russell]

Try just the layshaft and endplate,if that goes tight then suspect the rear hub bearing either being too tall or not seated correctly.

I tried that too, with layshaft and cluster in situ, no problem, it's only when the loose gears and cluster are fitted together that it all binds up

I had a similar problem when fitting my mates. First, I found the dowels were stopping endplate from sitting square, but once I'd sorted that, I found the kickstart teeth on the first gear were rubbing on the back of the endplate and locking up when tightened down.

Both of these problems were found after tightened the centre spider to pull the cluster through, which usually eliminates any tight problems.

Think i mentioned this somewhere in another topic on here about Cyclone fitting problems, I ended up cutting a channel in the back of the endplate to stop the 1st gear teeth rubbing; not ideal really, but put it down to combination of parts I was using; which included an MB rear hub bearing.

Hope this helps!

Cheers