What to do when assembling a commando gearbox?
Checking the end play on the layshaft. Assemble everything into the gearbox shell as described in the above section. Clean the sealing edges on the gearbox shell and the inner case, so as not to oil up the gasket in the next step. Place the inner case gasket over the studs.
How do you put a 4th gear in a transmission?
The protrusion of 4th gear lay fits against this inner race. Squirt some of the 90w gear oil you are going to fill your gearbox with on the two bearings in the gearbox shell. Fill a small tub with gear oil, so you can dip each gear and bushing into it prior to placing into the gearbox.
What to do if your ATV wont go into gear?
Troubleshooting an ATV that won’t go into gear or won’t shift gears can be quite complicated, but not always. Whether you’ll be able to address the issue on your own depends on the severity of the problem as well as your mechanical skill level.
Where is the layshaft located on a commando gearbox?
The top shaft is the mainshaft and the lower shaft is the layshaft. The shafts are positioned so that the inner case would go on the right. You can see the large mainshaft bearing, that would fit into the gearbox shell, still on the sleeve gear (4th gear main).
What kind of gasket to use on Commando gearbox?
Place the inner case gasket over the studs. If you want, you can seal this gasket to the gearbox shell at this time or leave it dry on both sides. Do not seal both sides of the gasket, since you may be removing the inner case to shim out the layshaft. I use Gasgacinch (part # 78-401001) to seal the gaskets in the gearbox.
Where does 3rd gear lay on a commando gearbox?
Fit 3rd gear lay and its bushing on the layshaft with the dog side going on the shaft first. Fit the 4th gear lay on the layshaft with the flat side going on the shaft first. Fit the inner race for the layshaft roller bearing on to the layshaft with the flanged end going on first.
How does the quadrant work on a commando gearbox?
The quadrant sticks through the inner case and has a rectangular area that it is allowed to move in. If the quadrant is not located on the cam properly, say one tooth too low, you will be able to get neutral through 4th gears, but not 1st gear.
How big are the shims on the Commando gearbox?
These shims come in four sizes (06-0775 — .005″, 06-0776 — .010″, 06-0777 — .020″ and 06-0778 — .030″). The following picture shows a couple of shims on the kickstart shaft, where you would place them.