Evening All
Update time......
Made quite a bit of progress today. I had bought some gearbox shims of various thicknesses during the week, so the first job was to remove the end-plate and try and get the end-float tolerance down. Originally it had a 2.0mm shim, but that was out of the 0.30mm tolerance, so I fitted a 2.2mm shim that I had spare. This brought it into tolerance (0.30mm), but only just, so today I fitted a 2.3mm shim which has brought it down to 0.19mm. I'll settle for that!
With the gearbox set up, I fitted a new seal into the drive-side bearing retainer. I have fitted a drive-side bearing which has a built-in seal which will prevent any gear oil from passing through. The gasket has also been fitted and sealed - belt-and-braces
The seal retaining plate was fitted with new socket-cap bolts which were Loctite-ed, torqued up and also centre punched to prevent loosening.
Next job was to look at the new crankshaft and check to make sure both webs were running true prior to fitting. This was done by setting it up between centres in my lathe and using a DTI gauge to check for any run-out. This was all good, so I fitted the bearing track to the tapered side. One thing I forgot to take a pic of was the fitting of the Woodruff Key. This was taken out of the old crank, then fitted to the new one.
With the crank ready, it was time to fit the new seals and bearing into the mag housing. Once done, the crank and mag-housing were fitted.
Next it was time to fit the clutch inner and outer bells, bearings, chain guides, cush-drive / front sprocket assembly and drive chain.
While all this was going on, I had the new clutch plates soaking in gear oil and to complete the transmission assembly, the clutch springs and plates were fitted and held in place with a new circlip.
To complete today's work, I started fitting-up the chaincase cover with the kickstart assembly. This all went together with a new O-ring, washer and circlip and also a new pinion retracting pin as the old one was nearly sawn in half
I would like to complete the engine during the week after work, but if not, it'll be at the weekend. Stay tuned for the next update and thanks for the comments.
Anyway, enough of the dialogue, here are some pics!
Jim
New shim fitted:
Gearbox and end-plate fitted for the last time:
Seal retainer plate fitted:
Mmmm, sexy! :
Checking crank webs for run-out:
Old bits laid out in order:
New bits ready (spacer ring not shown but was fitted):
Bearing track fitted to crank:
Mag-housing fitted up:
Crankshaft in:
Mag-housing fitted:
Back to the transmission:
Ready for clutch plates:
I didn't take a pic of the cluch plates being fitted
Kickstart parts prior to cleaning and fitting:
And how it sits until next week: