SECTION D7
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REMOVAL OF GEARBOX COMPLETE
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Though not normally necessary during overhaul,
we recognise that circumstances may arise which
make it desirable to remove the complete gearbox
without disturbing the engine although the primary
transmission must be dismantled fully. In these
circumstances remove the rear three crankcase to
engine plate bolts (or studs, depending on year),
the rear wheel and on 1971 and later models,
support the motorcycle by the lower frame rails on
a strong box and remove the centre stand. Remove
completely the gearbox top and bottom mounting bolt
and stud and remove the drawbolt assembly from the
right hand side of the rear engine mounting and
turn the gearbox anti-clockwise in the engine
plates viewed from right side. Force the rear
engine mounting rearwards until the cutaway part at
the bottom right hand side is clear of the
crankcase. The gearbox can then be turned further
and withdrawn horizontally from the right hand
side. Only in isolated cases will it be necessary
to take out the front mounting main bolt to provide
still further working space.
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SECTION D8
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COUNTERSHAFT (GEARBOX FINAL DRIVE) SPROCKET
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The countershaft sprocket is mounted on the
mainshaft sleeve (high) gear and secured by a tab
washer and L.H. threaded nut. The Commando overall
gearing should be varied by changing the sprocket
size. For the road going editions of the Commando,
the following sprockets are available:
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040480
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Sprocket
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19 teeth
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060931
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Sprocket
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20 teeth
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060721
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Sprocket
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21 teeth
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060759
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Sprocket
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22 teeth
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063420
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Sprocket
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23 teeth
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063421
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Sprocket
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24 teeth
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Changing the countershaft sprocket
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1
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Remove the outer primary chaincase, clutch and
primary transmission and inner primary chaincase as
in Section C14 to gain access to the sprocket.
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2
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Remove set screw and lockplate from sprocket.
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3
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The sprocket must be prevented from turning
whilst the left hand nut is released. If the
gearbox is in the frame, leave the rear chain
connected and apply the rear brake fully. If the
gearbox is out of the frame, pass a length of chain
round the sprocket, holding the ends securely in a
vice.
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4
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Noting that the sprocket nut is left hand
threaded, remove the nut and lift the sprocket
clear.
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5
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Before refitting the sprocket, ensure that the
sprocket spacer is in place on the sleeve gear
bearing sleeve.
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6
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Place the sprocket in position and if necessary
tap fully home with a tube drift.
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7
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If the original lockplate has been scrapped in
removal, have a new one available.
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8
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Fit and tighten the left hand nut fully, whilst
preventing the sprocket from turning.
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9
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Secure the lockplate with the locating screw.
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10
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Refit the inner chaincase, primary transmission
and outer chaincase as in Section C34 and fit and
connect the rear chain.
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