Allen's Commando (transmission) fix

Most of you that followed @ashman 's E-Start thread might recall that @IBA270 sold us the e-start kit, in a deal which began with me offering to trade some work on his Commando in exchange for my share of the cost. Well the deal went down the day he brought over the starter; he also brought me the bike.

And a nice one it is!



It's having issues with the kickstarter "locking up", and shifting is stiff. I initially suspected it MIGHT have one of the infamous dodgy layshaft bearings, and/or equally infamous crack in the case between the shafts, on the inside.

Of course it's "a bit of a fiddle" to get to the point where a proper inspection can even BEGIN...



It had neither issue...





So, next step is to carefully inspect the kickstart gear lump & ratchet, each cog, and the rest of the bits that can come into play. Also the shifting cam to see if it's grooves are wallowed out at all.

...stay tuned....

A bit of a sad note- slightly wrong tank mounting has caused the top yoke to bite the tank's previously nice paint. I'll adjust the mounts and touch up the paint by hand...

Just TOO MUCH STUFF going on!

Finally had a day to myself and so I got busy inspecting Allen's transmission guts. Everything looked hunky-dunky, till I got to the kickstarter sleeve gear!

I'm sure MANY of you have been HERE... (look close)



Ah, yep! That's the problem, alright...



Cracked all the way in. That'll sure cause jamming and fussing.

New bits on order.

Turns out Allen has TWO NYCNorton sump breather kits.

Spare has been SOLD.

Put in a couple more hours yesterday, reassembling Allen's bike. Looks like I'll be pulling the gas tank to flush it real well before rigging up the fuel system.



Spotted a perished oil tank mount buffer, new ones on order. These things should be offered in a much more durable material...



Gearset re-installed, awaiting the new kicker sleeve gear & 1 qt Klotz transmission lube.



The mainshaft circlip went walkabout, so the project is on hold at this point.

Got a lot done on Allen's Norton Commando now that all the parts came in.

Filthy...



Nice and clean with new kicker ratchet shaft installed-



Buttoned up!

Primary drive installed with new mainshaft retainer circlip (the old one went walkabout), and new lock tabs



Backside perfectly shimmed...



All new Barnett clutch pack with new pressure plate. Nice and tidy!



Next: hydraulic clutch actuator & NYCNorton sump breather...

Hmmmmmmmmmm... I don't think that trick fold-out kicker is going to clear the shifter nub...

grandpaul said:

Put in a couple more hours yesterday, reassembling Allen's bike. Looks like I'll be pulling the gas tank to flush it real well before rigging up the fuel system.

View attachment 125596

Spotted a perished oil tank mount buffer, new ones on order. These things should be offered in a much more durable material...

View attachment 125597

Gearset re-installed, awaiting the new kicker sleeve gear & 1 qt Klotz transmission lube.

View attachment 125598

The mainshaft circlip went walkabout, so the project is on hold at this point.

View attachment 125599

Click to expand...

It's been twisted by not tightening correctly (I.e. holding the hex in a neutral position whilst tightening the bottom nut) leading to early failure. Who knows, It may have come from the factory like that though.

cliffa said:

View attachment 125663
It's been twisted by not tightening correctly (I.e. holding the hex in a neutral position whilst tightening the bottom nut) leading to early failure. Who knows, It may have come from the factory like that though.

Click to expand...

I think it's just old, but improper tightening doesn't help...

On the shifter being hit by the kickstart lever, with much the same setup I shortened the toe peg on the gear change lever until the kickstart cleared.
Took about 15mm off the end and its still a good length and usable.