Shimming layshaft

I used the ball bearing so I would not have to shim the lay shaft but when assembled I had about .070 end play on the kicker shaft with the inner cover in place...ouch. All went together so easy. The bearing I took out looked like new even though it was original. Bike only has about 6k miles on it though.

So I have some iso shims on order to try and get this down to .010. I never bothered to check end play before I took it apart.

So how much end play have other run into? As near as I can tell you can't hardly put this thing together wrong. Put bearing on the layshaft all the way to the shoulder. Put layshaft and bearing into case seated all the way. Then it is what it is.

Anyone want to restore their commando to 100% original with a good portugese layshaft bearing? I'll give it to you .

lrutt said:

......Anyone want to restore their commando to 100% original with a good portugese layshaft bearing? I'll give it to you .

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that's funny Irutt

Are your new cover gaskets thicker than you old ones.
You can, and many do, go without a inner AND outer cover gasket.

Also, many people shim for the ball bearing too. Not as necessary as the layshaft will remain stationary but it will reduce side force on the bearing cage.

I do not like the shimming cause it reduces the landing area of the kick start pawl. I would try the gasket approach and/or find thinner gaskets.

Ugh, "The Some" who leave out gear box gaskets, includes only hobot and my old infirm or dead mentors, so no one but hobot and his prior mentors don't need to shim lay shaft. Every time I've posted this here its ignored or discounted as stupid advice - so you mentioning it have stained yourself forever with dreaded hobot camp soot. They also advised me to use ATF in gearbox and primary a couple+ decades ago, which I agree - is un-needed - till staying in lower gears at hi throttle rpms to stay ahead of elite sports bikes in the tights... Oh yes its was so worth it to destroy Peel's 1st set of sleeve bushes for the strangers and my own lasting reactions, till later no gaskets holding the ATF in. After that 3rd gear teeth are next weakest link - if ya got the power to bow-twist the shafts up like Ms Peel's against the grain Combat engine did. Oh yeah may also notice the clutch lever pull may be easier too not even notice with the increased sweetness of plates release and engagement. So I await the first report of anyone else on this forum leaving out a gasket or two in AMC boxes. i use Hylomar but about anything seals the low heat and vibe gear boxes. Peels would get too hot to touch, similar temps as primary or TS cover, after hours of dicing the twisties for sense of the wonderous intensity she tested my own fluids retaining.

Ya know, with a ball bearing mounted, .070" is not all that far out and not uncommon. I'm sure there are many at .100" and more. You may, after torguing, be at an exceptable dimension.
Again, we're not talking about the layshaft floating around, just the kickstart shaft.

Edit:
I would rather have a little too much play than too little.
Things tend to get hot and tighten up.
I like to keep it on the free side.

lrutt said:

So how much end play have other run into?

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Minimal, on mine, after installing the 'Hemmings' ball bearing.
Layshaft bush thrust face wear can increase shaft end play.

pete.v said:

Again, we're not talking about the layshaft floating around, just the kickstart shaft.

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Layshaft end play is governed by the amount of kickstart shaft play.

I realize the layshaft should NOT move with the ball bearing in place. Bearing was tight on shaft and tight in case. The old britts writeup indicates .010" end play on the loose end. Putting the shims between the kick shaft and the outer case as recommended would keep the kicker pawls more engaged. .060 is almost 1/16". I've got the shims on order so I'll stay with the gaskets and shim at .055 or so and check play.

Seems like suggestions run the gamut. And I'll keep an eye on it after I get it warmed up to make sure I still have some play but I feel the old britts recommendation at .010 takes that into account and sounds reasonable.

Was just kind of curious as I didn't really find this detail in any searches.

I have to say, that gear box with only 6k miles on it looked beautiful inside. Absolutely no pits, marks, or anything. Bushes all nice and tight. Kind of nice for a change not to have some grungy old box all lose and chewed up.

Thanks for the feedback.