Markets wax and wane, but through about 10 years within the 14 years I was refurbishing, restoring, overhauling and custom building old bikes, I sold 9 complete Commando engines for $1,000 each (plus shipping), needing overhaul, but nothing destroyed and the major triad components included (power unit, primary drive, and transmission; not always with cradle included). These days they don't sell for that much, although that fact is somewhat puzzling to me.
Anyway, I plan to do a financial analysis of all the Commando engines I've rebuilt over the years (around a dozen) and come up with an average or a range of costs incurred.
Basically (from memory, when the main bits were there and nothing destroyed):
Full gasket set - all three components
Full bearing/bushing set (all 3) including Superblends & approved layshaft bearing every time
Full seal set (all 3)
TYPICALLY new valves and guides (not always, depending on wear status and client budget)
Full head remediation almost always, DEFINITELY valves & seats ground or lapped for best results
Cylinders bored & honed
Pistons replaced 95% of the time, rings replaced 100%
Cam inspected and polished, only replaced with Megacycle at client's direction, only 1 destroyed cam found
Cam followers polished (VERY infrequently required replacements, maybe twice)
Rockers polished
TYPICALLY didn't require new valve springs (maybe 30% of the time)
Head & cylinder decks checked and resurfaced as minimally as required (maybe 10% of the time needing resurface)
Crankcase mating faces & deck checked and resurfaced as required (less than 10%)
New cam & primary chains
New camchain adjuster foot w/ nylon block
Oil pump disassembled, checked and polished or resurfaced (50/50)
Crank disassembled, throughly cleaned including galleries, (all new hardware 50/50)
Crank journals polished, (ground about 20% of the time)
Rods checked, only 1 set needing oversizing out of ALL (hardware replaced 50/50)
Check and resurface clutch plates (replace friction plates about 50/50)
Mainshaft oil seal & lock washer for clutch hub. Clutch bearing replaced 10% of the time
All new tab washers
Primary mainshaft felt seal replaced (bugger) 50/50
Replaced final drive sprocket as required or directed 50/50
RARELY ever needed to replace any gears, shafts or forks
Only replaced ONE crank, and ONE pair of rods due to buggering by others
Replaced 2 sets cylinders due to max limit
Never replaced a crankcase, primary case, or transmission box
Replaced ONE head because cost to replace with a nice e-bay head was cheaper than a total rebuild which was still possible
I'm sure I'm overlooking a few items, but if you go to the Andover site and price out all of the above, you'll get a fair idea as to the cost of an overhaul.
