Broken again

Discussion in 'Norton Commando Classic Motorcycles' started by PJFlynn, Apr 15, 2018 at 3:17 PM.

  1. PJFlynn

    PJFlynn

    Joined:
    Apr 26, 2017
    Kick starter nor engaging. Gearbox cover stuck on hard.any necessary upgrades while I'm in there.
     
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  2. Danno

    Danno

    Joined:
    Feb 7, 2010
    Probably just the pawl. Get good gaskets. I like the ones from MAP Cycle. Uprated seals at the K/S shaft and gearchange shaft. X-rings as opposed to O-rings.
     
  3. N0rt0nelectr@

    N0rt0nelectr@ VIP MEMBER

    Joined:
    Sep 15, 2014
    Get a genuine pawl, there maybe some cheap after market ones still out there. Knew a person who went thru several in a very short time, they were sourced from Domi Racer.
    John in Texas
     
  4. grandpaul

    grandpaul VIP MEMBER

    Joined:
    Jan 15, 2008
    The DomiRacer enterprise was bought out by someone else. They may or may not still have the inferior stock...
     
  5. hobot

    hobot

    Joined:
    Oct 19, 2005
    PJ- forum members are being gentle with you, as they were me in my beginning, only mentioning simple stuff to comfort you till actually trying to open up the fossil in first place, so not listing the few (many) other things that can cause KS to swing free. Beside the moving rachet pawl, there's the steel rachet stop, that's riveted on and KS works through the big 1st gear cog, which has the thinnest weakest wear prone to fracturing bushing, that can mess with KS engagement. If you got the kick lever off w/o mentioning much trouble, good omen. Outter cover removal can make you feel so incompetent as it hangs u on the shafts and shifter peg. I found levering more at bottom eases it off and replacing it by starting/bumps more at the bottom seems less frustrating. Once outer cover off the rest is comes apart rather too easy, which makes reassembly less easy. If gearbox only on 1st or 2nd time its been opened, expect a couple hindered bux in parts, bushes, bearings etc to replace. Manual and respected advisers all use gaskets, but I ran out of them so tired just goop to be pleased it also took care of the shaft end play shimming tedium delays. Oh yeah need to learn about the several options to seal KS shaft.

    Btw the sleeve bushes that spin in 1-2-3 gears, sit below resting oil level, sling any oil out while in lower gears, to easy run dry in low gears, only getting some oil by drain down past thin bush cervices in 4th, so remember what it takes to replace these bushes while delaying shifting to 4th. Factory pair of sleeve bushes tend to slide out of best load baring positions, so can put a worn short bush in between or get the longer set/pair. Not bad idea to oil groove these. Oh yeah likely have to ream some bushes to fit so have those tools on hand or farm out.

    Once you get back to replacing outer cover, with all the rusted stuff cleaned up and secured, spray with paint, color or clear to help keep it that way. Easy to over fill with oil, but no problem, as will leak back out to seek its own level to note there after.
     
  6. PJFlynn

    PJFlynn

    Joined:
    Apr 26, 2017
    Nothing in workshop Manuel about fixing kick start. Guess I'm on my own
     
  7. PJFlynn

    PJFlynn

    Joined:
    Apr 26, 2017
    Ps thanks hobot
     
  8. PJFlynn

    PJFlynn

    Joined:
    Apr 26, 2017
    Any info to help?
     
  9. Sport75073

    Sport75073

    Joined:
    Aug 24, 2016
    Phil Radford of Fair spares in California offers a service for pre MK3 covers which includes machining for an outer seal on the kick start shaft and gear shift shaft. Plenty of Norton and Norvil parts too.

    http://www.fairsparesamerica.com/services.asp
     
  10. Ron L

    Ron L VIP MEMBER

    Joined:
    Feb 27, 2004
    DomiRacer is closed for good. All stock was auctioned off a few years ago.
     
  11. L.A.B.

    L.A.B. Moderator VIP MEMBER

    Joined:
    Nov 20, 2004

    Follow the manual instructions regarding removal of the outer and inner covers.
    Remove the kickstart shaft from the inner cover, push out the pawl pin taking care not to lose the spring and plunger, check there are no cracks in the shaft, check the ratchet teeth inside 1st gear for excessive wear, check the pawl plates for wear, fit new pawl, reassemble.
     
  12. Bodger

    Bodger VIP MEMBER

    Joined:
    May 9, 2017
    After all the fasteners are off, a heat gun all around the edge of the outer cover works a treat on a stuck outer cover.
     
    eskasteve likes this.
  13. 84ok

    84ok

    Joined:
    Aug 10, 2014
  14. grandpaul

    grandpaul VIP MEMBER

    Joined:
    Jan 15, 2008
    ...as I stated.
    The winner of the auction may or may not still have the stock of those inferior bits.
     
    concours likes this.
  15. delagem

    delagem

    Joined:
    Jan 27, 2018
    When I pulled my outer cover to change over to X rings (which does indeed seem to have stopped my leaks), I couldn't budge the cover. Then, I pulled the clutch lever in; pop! Jumped out about 1/4"...
     
  16. Danno

    Danno

    Joined:
    Feb 7, 2010
    A couple of reluctant covers I've dealt with come right off with the application of some heat and a few whacks with a rubber mallet while pulling outward on the offending piece.
     
  17. Gilesy

    Gilesy

    Joined:
    Aug 27, 2017
    As above Old Britts, or Mick Hemmings does a DVD of gearbox rebuild, available from NOC.
     
  18. PJFlynn

    PJFlynn

    Joined:
    Apr 26, 2017
    Nobody said how to get the mainshaft nut off.
     
  19. bill

    bill

    Joined:
    Jun 1, 2003
    impact gun. it is a right hand thread.

    t
     
  20. L.A.B.

    L.A.B. Moderator VIP MEMBER

    Joined:
    Nov 20, 2004
    Manual, section D4,3.
     

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