Norton Commando Workshop Manual

## Gearbox

# D

During re-assembly ensure that the spring retaining washer is fitted over the main spindle of the pawl carrier and that the spring has been assembled over the ratchet plate as illustrated in Fig. D8. Tighten the stop plate set scrows and assemble the splined end of the pawl carrier past the 'O' ring in the cover. Locate the spring peg between the logs of the spring and push the pawl carrier fully home, engaging between the legs of the spring. Check the carrier action and that the spring is correctly located. The set screws should be tightened only when the action of the pawl carrier has been checked for full freedom of movement. Now fit the pawl spring with its double cranked leg downwards, ensuring a minimum but perceptible clearance, between the two legs of the spring and the pawl.

### SECTION D12

### REFITTING THE GEARBOX OUTER COVER

Having dealt with the outer cover as described in Section D11, ensure that the joint facing is perfectly clean and proceed with assembly as detailed below:

1 | Fit the inner cover to outer cover gasket, retaining in place during assembly with a smear of grease. Ensure that the gasket engages satisfactorily over the cover dowels.
2 | To ensure cover alignment during assembly retain the ratchet spring in the central position with the index finger of the right hand and guide the case over the kickstart shaft with the thumb of the left hand engaged through the filler cap hole.
3 | Drive the outer cover fully home and assemble the five screws of equal length to retain the outer cover in position. If the cover is very difficult to push into position, check whether the pawl has rotated due to the pawl scissor spring not having been held securely in position, during final assembly. The cover should be removed, the ratchet pawl reset and re-assembly undertaken.
4 | Fit the gearshift pedal and kickstart crank, then check the action of the gearbox, rotating the rear wheel as the gear pedal is moved to the various gear positions. If all is well, assemble the gear position indicator pointer and replenish the gearbox with oil.
5 | Connect the clutch cable through the inspection hole in the gearbox outer cover, engaging and locating the nipple in the operating lever.
6 | Finally assemble the gasket, inspection cover and screws to the gearbox outer cover, and check the security of the drain and level plugs.

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