1978 390 Auto build

I can't afford to take short cuts. I knew the motor had been a parts donkey when I bought it, and the sprags had been swapped out to make another gearbox. The rest of it I am treating as the same situation. I am finding that the odd small part, spacer, washer etc is missing.

Just can't wait to ride the damn thing.

expensive maybe but at least the autos are fairly simple..hope it works well

Looks good nice work!

Grouty , where did you get the freewheels and how much ?

Michel - see PM

I have finally managed to rebuild the 2/3/4 gear cluster. All thanks to Stormer (Steve) and a set of nos 2/3 and 4th shoes.
Time to put it all together.

The 3rd gear cog was warmed with a blowtorch and fitted over the shaft. A bit of a pain to hold it, hold the key, and tap it home ! All with very warm fingers ! New circlip.

2nd gear is fitted the same way. New circlip again. I did find that there is a fine line fitting the gears. I needed to lever 3rd gear back up hard against the circlip to stop it having a tight spot. It all spins sweet as now.

I had ordered a new dog engagement gear. This came without the bearing fitted. Again, warming the gear and fitting the bearing is easy. It needed a little easing on the dog teeth inside to slip over the brand new mainshaft. You can just see the shiny marks where I have applied the Dremel.

The other side of the engagement gear showing where I had to grind off the high spots. It was less than a thou !





This shows the original gear compared to the new one. The old one has seen some action and modification in it's life.





This is the new mainshaft and the old. There has been some alterations to the end of the old shaft. Very nicely done with an angle grinder. I think it would have worked fine, but as I've gone this far with the wallet in tow, I am not taking a chance.

Had a good morning today ! Managed to press out the old main shaft, and press in the new one complete with new woodruff key. All the bits ready to finally (I hope) assemble this lot.






Well .... that took all of 5 minutes !




It all slotted in nice. Checked the engagement lever works too.





Lapped in the 1st gear taper on the crank. You can see by the dull colour on both the crank and clutch hub.





Realized that I was missing the spacer washer between the bearing and clutch drum here. Just another part that was missing from this engine. I have found that a thrust washer from a ZZR600 Kawasaki is the same. I'll have that next week. So I should be able to button up this side fairly soon. Just need to make a spring cover plate for the 1st gear springs. Many thanks to Michel for posting the sketch. I will try making one to that pattern and see how that fits. I also need to replace the temporary M5 hex headed screws for the main bearing retainer with some standard 12.9 Allen screws. A bit of Loctite too I guess.
Can any of you Auto guru's see anything I have over looked ??

Looking real healthy! Can't wait for the ride report.

Looks good nice job!

View: http://www.youtube.com/watch?v=V3OuHPZuJZc

Mmm, you need this type of spring cover !

Looking very good Ian

It was all going well Steve. I hit a bit of a snag yesterday. I dropped the first gear clutch back into place and noticed that the shoes were not sitting in square. The tips were protruding slightly above the lip of the drum. Looking further it seems that someone in the past has not used the puller correctly ! Looks like they only screwed the M6 studs into the first part of the hub, and not all the way through into the lower part. Hence they have pulled on the top and distorted it allowing the shoes to have too much play in the up and down motion. I also noticed a small hairline crack on the inside part of one of the hub tabs. I thought I would check it ..... bad idea ! (or not). I moved it with a pair of pliers and it broke off. Probably just as well, because it would have failed sooner or later anyway.
I have emailed Jef Bens to see if he has another one. It looks like I have the early type hub too.

I can also have a look in the shed tomorrow if you want?

Thanks Steve, but I think there is one winging it's way to me now. Hopefully normal service will be resumed in a few days. In the mean time I will be changing wheel bearings tonight for a mate with his Yam 250WR. Not as good as working on a Husky, but it will have to do. ( I hate modern bikes !)

Grouty! You just reminded me to stay heck away from an automatic! Unless you are working on it. Nice work !

Me working on it ..... the proof will be how long it lasts
My intention is to give it the best start I can. If it spits it's dummy soon after, then it will be running true to course. If not, then I I'll have to pinch myself as it is obviously a dream

I just love rebuilding them anyway. Better still if it is a Husky.