1978 390 Auto build

clean and sweet looking build

Had a few hours yesterday and decided to bite the bullet and remover the needle bearing for the idler gear. It did take a while but old one out, new one in.
I then thought I would have a go at re-assembling the kickstart mechanism. Got it spot on first time !

I was just about to locktite the two countersunk screws when I noticed a bit of a problem. See picture ....
The search is now on for another one. I figured that if it broke it would do some major damage, and starting the bike would be impossible.
The cracks go halfway through on the left side, and nearly all the way on the other.

I'm posting a spare one in the morning of my parts engine, but it is definitely more a Steve than an Ian part, i.e. rough!!

You're a star Steve. Thanks.

John, I did think about machining a new one. But the "ramp" on the spring end needs to be just right, and I have feeling it's a bit tougher than bar stock.
EN24T was going to be my preference.

But Steve has come to the rescue, so I can spend that time doing something else :-)

After a great deal of thought I decided to fit a new spring stop. The one ordered for 12€ (about £10 plus post) was supposed to be like the damaged one, but turned out to be from a later model (without the countersunk holes). It fits perfectly, and clears everything around it. So I'll run with it and see what happens.
The one Steve kindly posted me was a bit of a cut and shut, and I would worry it may break again.

The wife and kids are away for a day or two....... so I made use of the kitchen, freezer, oven and a glass of lubricant.
One half of the crankcase is now together. Even with the frozen crank, hot casing and special tool it was hard work. I put this down to the crank stubs being new !
All cleaned up now, she will never know

I know ! I don't think she really minds though. I did get caught cooking the fork sliders and yokes in the oven a while ago. She came back one evening with the kids and seemed impressed that I was obviously cooking dinner. She went to look in the oven and just remarked "oh, that's not dinner" and closed the door.
Same MO with the dishwasher too ! I just don't flaunt it. If she see's, that's ok. If she doesn't then even better.

I had time tonight to measure the new clutch side crank stub, and the I.D. of the new main bearing. WOW .... there is 3.5 thou difference in dia.
That is going to take some effort !
Is this normal ?
The new clutch side stub is NOS, and the bearing is the correct one.

A small (but expensive) box arrived on Friday. This little lot should rebuild the auxillary (sprocket) shaft.

All parts for the aux shaft cleaned and ready to go ...

Two needle rollers and two sprags for second gear.

Two needles and one sprag for 3rd gear.

One large needle/ roller bearing and one sprag for 4th gear.

4th gear hub was a bit of a bitch to get on as the bearing and sprag are a bit loose. Once fitted it is super smooth. The only part missing from my shaft is the thin spacer that goes between the solid disc and the casing bearing. The small piece bottom left is the tube for the oil seal to run on just behind the sprocket.

All slotted into place for the time being. I will pop it out to fit the spacer inside when I have one.
As you can see the casings are finally together.

Also had time to look at the first gear clutch. All cleaned up and almost ready to go. I will be replacing the needle bearings and sprag in the hub. If you look closely you can see a few missing 'dog bones' from the sprag. The springs are ok, not brilliant ! I ill try them and see. I have re-cut the grooves in the shoes, and fettled and polished the spring holes.

Looken good!Your not taken any short cuts for sure