kickstart question

gentlemens….I hope to give my 72 frame/73 engine commando project its first start attempt later this week after 14 months and several thousands of dollars invested...all wiring is done now time the pazon surefire...however, i have noticed that on occasion when I put foot to kickstart lever that it seems to 'miss' the first tooth in the bowels of the gearbox with an accompanying click or crunch and engage on the next one to complete the kick..it only does this now and then and by carefully pushing on level til I feel it 'catch' doesn't do it at all....is this normal? I hope I have described the situation clearly....wish me luck on the startup ..

Your pawl is worn out. Very common. It has lost it's sharp engagement edge with the teeth inside first gear which it engages with when kickstarting. Ignoring this issue will start rounding off the teeth until it's too late and then you must replace 1 st gear as well. Some pawls are made harder than others.

alan hodge said:

i have noticed that on occasion when I put foot to kickstart lever that it seems to 'miss' the first tooth in the bowels of the gearbox with an accompanying click or crunch and engage on the next one to complete the kick..it only does this now and then and by carefully pushing on level til I feel it 'catch' doesn't do it at all....is this normal?

Click to expand...

Probably a worn pawl as suggested by Torontonian. Always try to engage the kickstart ratchet mechanism before kicking.

thanks does gearbox have to come out of frame for pawl replacement?

No, although outer and inner covers must be removed.

https://www.oldbritts.com/gearbox_info.html
https://www.oldbritts.com/gearbox_a.html
http://www.doov.com/apps/nortoncompanion/index.php/workshop-categories/d-gearbox

It's also an opportunity to check the driveside layshaft bearing and upgrade it if it's found to be a standard 6203 ball bearing.

http://www.doov.com/apps/nortoncomp...des-modifications/25-layshaft-bearing-upgrade

Torontonian said:

Some pawls are made harder than others.

Click to expand...

I agree with this. I ruined my pawl the first night after overhaul of the gearbox with new pawl.
The ignition was not spot on and kick back, probably with bad engage.

The picture shows new pawl that is ruin. I think it's too hard.

I destroyed the pawl on my first Commando back in 1971 by stupidly "jabbing" on the kick starter
instead of making sure all is engaged before keeping contact whilst thrusting with all 120 pounds.

1up3down said:

I destroyed the pawl on my first Commando back in 1971 by stupidly "jabbing" on the kick starter
instead of making sure all is engaged before keeping contact whilst thrusting with all 120 pounds.

Click to expand...

My first post (!):
That blasted Norton kicker for the AMC 4-speed was always a source of contention on our Commandos-- back in the day when Commandos were a current make. (The AJS kicker was superior.) And that blasted layshaft bearing-- what a disappointment that was. For the pawl: the trick was to line up the sweet-spot and swift-kick it, with bike off any stands. Of course, being under 140 lbs. teenagers, we just had to look on with awe at the older guys that could.

Edited: cited erroneous kickstarter.

Maybe also check for end float of the kickstart shaft and shim if necessary. The full width of the pawl does not engage with the dogs in the first gear, as shown by Kvinnhering's photo, and the engagement is reduced even further by end float.