Cyclone 5 speed locking up when tightened endplate

[Cutdown69]

Hi
I have a Cyclone 5 speed gear box, and was experiencing difficulty selecting gears, so stripped it down
I noticed that the layshaft had some type of corrosion so decided to replace with a new Casa layshaft

https://postimg.cc/gallery/9MQCp4t


I fitted the new layshaft and have torqued up with rear hub
However, fitting the endplate locks it up, even with smallest shim (0.8mm)
I don't know whether it's the rear bearing (which I haven't replaced) or the endplate is warped??
I'm not sure what I should do next
https://postimg.cc/gallery/9MQCp4t

[Warkton Tornado No.1]

With no gears in place, endplate fitted, but layshaft torqued up, the layshaft should spin freely. Obviously that is the first check.

If that is all fine, without the cluster or any big shim fitted, the assembly should spin. If that is the case, now the clearance between the endplate & first gear recess can be measured to determine required shim.

Let us know how you get on.

[Cutdown69]

Hi, thanks for suggestion I took first gear out and secured endplate and yes layshaft locks...rear wheel won't spin....does that mean possibly layshaft not seating properly (rear hub bearing issue?) ?

[Warkton Tornado No.1]

I seem to be making a habit of questioning the quality of re-manufactured products but - bearing in mind that some manufacturers claim theirs to be better than OEM - I hardly think they require my apology. I’m not expecting a Christmas card from Casa this year….

You have the layshaft that the Casa product was intended to replace, so I would definitely try the basic assembly I described to see what happens. If such a trial proves anything, it will be either that your new layshaft is at fault or the hub bearing is causing the issues. Unlikely if it is an OEM bearing. I have an ominous feeling that that too, may be Casa……Gulp!

[hullygully]

compare the hub bearing with an Italian one, I had an Indian one that was 0.25mm wider than its European counterpart