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Post by jon on Jun 26, 2022 8:34:19 GMT 1
Dusty mate, your work is always flawless, but could I suggest you try using white spirit instead of petrol for cleaning parts? It works just as well, it's much safer, and has a lot less noxious odour. I always add just a tad of oil to it, to prevent any rusting when it dries off. Only downside would be it might not dry off quite as quick as petrol. Both around the same price these days too. Money no object I’d go the other way regarding drying time of cleaning solution. I used some fast dry panel wipe (for degreasing in between layers of paint) to clean my wiring loom connectors. I thought at the time I might use it to clean the components on my next engine rebuild. These days I expect it’s not to more expensive than petrol? Jon |
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Post by dusty350 on Jun 26, 2022 10:21:11 GMT 1
Morning fellas  I use petrol as I usually have a can or two in the shed. I had put a few litres in the Fzrd tank when I got it, but now that bike is stripped, I have some fuel going spare. I do find petrol is as good as anything else I've tried - really cuts through greasy muck. As an aside, I bought some White Spirit recently - needed some as I was decorating my daughters flat. Didn't realise till I got home it's now called "Cleaning Spirit" ? It struggled to clean my brushes after painting - definitely not as good as it used to be. Will look elsewhere for good old White Spirit - I just hope the ingredients haven't changed to make it less useful  It really was weak. Dusty |
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Post by dusty350 on Jun 26, 2022 20:17:12 GMT 1
Selector drum stopper arm is next. I drill the rivet out on my pillar drill, as I want to fit a bearing instead;  20220625_220507 by dusty miller, on Flickr This will mimic the Sift Pro design, but is a fraction of the Shift Pro price, which was 60 quid last time I looked. This bearing will cost just a few quid from Simply Bearings. I used an SKF W 605 2RS1;  20220625_220540 by dusty miller, on Flickr It's a shielded bearing but I remove the rubber covers with a Stanley blade to allow oil to penetrate more easily. Note the bolt has a very shallow head - this is to clear the drum;  20220625_221204 by dusty miller, on Flickr I use the original Yamaha spring. The Shift Pro uses a weaker spring, but there is a consensus that the stronger, standard spring works better with the modded star and stopper arm. The spring is pushed fully into place;  20220625_174552 by dusty miller, on Flickr And the stopper arm is wiggled into position - an be a bit fiddly;  20220625_222142_06 by dusty miller, on Flickr That's the stopper arm modified and fitted. I spin the engine around to fit the neutral switch and O ring;  20220625_223806 by dusty miller, on Flickr Neutral switch is £23.03, and the O ring is £2.89. I apply red rubber grease to the O ring, and a little on the casing where it pushes in to save any damage to the O ring. 3 new bolts, but be careful not to overtighten or you can split the plastic housing;  20220625_224951 by dusty miller, on Flickr Dusty |
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Post by donkeychomp on Jun 26, 2022 21:51:19 GMT 1
Dusty I'll PM you mate.
Alex
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Post by JonW on Jun 27, 2022 0:24:46 GMT 1
Good work Dusty, loving the home made shift pro, we need a name for that .... ShiftAmateur? ShiftyPro? er... I'll get me coat...
On me way out tho... where did you get the thin head bolt you used, or did you turn it down in a lathe?
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Post by dusty350 on Jun 27, 2022 6:34:11 GMT 1
Hi Jon, I think it's one Alan Kelly supplied as a spare last time he did the star mod for me. I used a button head hex bolt the very first time I did one, but the head would "just" come into contact with the drum body when the bearing sat between the points of the star. This very low profile doesn't touch. The drum is easily turned by hand with the lower points on the star, and the bearing has more contact area with the star due to being much wider than the standard part. Dusty |
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Post by dusty350 on Jun 27, 2022 7:46:52 GMT 1
Gear selector adjuster bolt next;  20220626_203741 by dusty miller, on Flickr The cam bolt is £3.49, the lock nut is £ 2.89, and the tab washer is £2.65. Loosely fitted for now, as I need to adjust the bolt once the gearshaft is fitted;  20220626_205117 by dusty miller, on Flickr Dusty |
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Post by JonW on Jun 27, 2022 14:21:19 GMT 1
Hi Jon, I think it's one Alan Kelly supplied as a spare last time he did the star mod for me. I used a button head hex bolt the very first time I did one, but the head would "just" come into contact with the drum body when the bearing sat between the points of the star. This very low profile doesn't touch. The drum is easily turned by hand with the lower points on the star, and the bearing has more contact area with the star due to being much wider than the standard part. Dusty Ahha, its a modded bolt, mystery solved. I assume there wasnt much of anything for a tool to hold it when you did up the nut? |
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Post by dusty350 on Jun 27, 2022 14:50:25 GMT 1
Its a hex (allen) head bolt so it wasn't a problem. I'm not sure of it was a special bolt to start with ? I think Al supplied it but its 4 years ago now so I could be wrong.
Dusty🙂
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Post by chrisg on Jun 29, 2022 14:28:14 GMT 1
Nice thread as always Dusty. I find those little JIS screws, the domed and the countersunk ones offer most resistance to removal. I put a bit of heat on them once, but accidently melted the plastic tacho sprocket, so be careful anyone who tries that! Are those little screws loctited in at the factory? I know some engine builders loctite them on assembly. Think i may need to invest in a JIS attachment for my impact gun. |
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Post by dusty350 on Jun 29, 2022 17:33:38 GMT 1
I don't think so. There is no evidence of loctite on any of the threads on the old fasteners.
Dusty
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Post by dusty350 on Jun 29, 2022 19:11:25 GMT 1
The gearshaft fitment is next. I found mine on ebay, for £69 plus a few quid for post. Fowlers list them at £101.82   20220626_204103 by dusty miller, on Flickr You need to rob the old shaft of it's plastic spacer, and the spring that sits over the cam bolt adjuster;  20220627_083546 by dusty miller, on Flickr The spacer slides straight onto the new gearshaft, but the spring has 2 grooves worn into it by the cam bolt. I decided to order a new spring from Fowlers to save any potential issues the wear may cause with adjustment. It's £4.00 from Fowlers but still hasn't turned up, in spite of first class Royal Fail post, so I cant show you yet. In the meantime, these are the half rings;  20220626_202824 by dusty miller, on Flickr One of the large ones is for the crank, the other large and smaller ones are for the gearbox bearings;  20220626_202849 by dusty miller, on Flickr And finally, the new gearbox bearings;  20220626_203502 by dusty miller, on Flickr Dusty |
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Post by donkeychomp on Jun 29, 2022 21:22:43 GMT 1
Dusty can I ask why you changed the gearshaft? Or is it just a standard thing when building an engine?
Alex
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Post by dusty350 on Jun 29, 2022 21:35:55 GMT 1
Hi mate It's got a wear groove where it contacts the oil seal. Not as bad as some to be fair, but I want it to be the best it can be, so I bought a new one. I have a few worn shafts now. I did consider taking them to Glen to see if he can drop some weld around the wear groove and then machine it back to stock dimensions, but that's a job for a rainy day ! Dusty |
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Post by midlifecrisisrd on Jun 29, 2022 21:43:38 GMT 1
Great work as usual Dusty
For anybody building an LC engine on a budget a grooved ypvs shaft can be fitted to an LC as the grooves will be 5mm or so out with the seal due to the shaft being slightly longer than LC and the LC gearbox being narrower
Handy if you've built a few motors and have some old ones
Steve
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Post by dusty350 on Jun 29, 2022 22:42:09 GMT 1
Good tip Steve  |
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Post by JonW on Jun 30, 2022 0:34:06 GMT 1
Great work as usual Dusty For anybody building an LC engine on a budget a grooved ypvs shaft can be fitted to an LC as the grooves will be 5mm or so out with the seal due to the shaft being slightly longer than LC and the LC gearbox being narrower Handy if you've built a few motors and have some old ones Steve Ive done this with good results as well. Someone probably should set up a 'swap shop' somewhere on the forum for this? |
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Post by shaunthe2nd on Jun 30, 2022 7:18:14 GMT 1
I fitted the offset seal kit on my last build as I had one kicking around. Saved the cost of a new gearshaft.
Another option.
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Post by dusty350 on Jun 30, 2022 7:49:43 GMT 1
Hi Shaun, Yea, I fitted one too to my 400 hybrid. The gearshaft had a wear groove and you can no longer buy the shafts for the aircooleds. Yambits do a pattern part but they dont get good reviews !! With the cases apart, I like to do the insert mod, but if the engine wasn't getting stripped, the external bush is a great alternative. Dusty |
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Post by steeley on Jun 30, 2022 8:48:32 GMT 1
Hi mate It's got a wear groove where it contacts the oil seal. Not as bad as some to be fair, but I want it to be the best it can be, so I bought a new one. I have a few worn shafts now. I did consider taking them to Glen to see if he can drop some weld around the wear groove and then machine it back to stock dimensions, but that's a job for a rainy day ! Dusty Nice job you are doing there dusty . Some time ago while rebuilding one of these engines i had a spare gear change shaft but that area you are talking about was bad so i welded it up and a chap i know machined it back for me for a pint . Which i thought was a bargain considering the price of a new one . I also fitted the bush mod to the case . |
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Post by lcmarky on Jun 30, 2022 18:03:07 GMT 1
Lovin' the thread Dusty & comparing notes....
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Post by chrisg on Jul 1, 2022 18:57:21 GMT 1
Dusty mate, your work is always flawless, but could I suggest you try using white spirit instead of petrol for cleaning parts? It works just as well, it's much safer, and has a lot less noxious odour. I always add just a tad of oil to it, to prevent any rusting when it dries off. Only downside would be it might not dry off quite as quick as petrol. Both around the same price these days too. Money no object I’d go the other way regarding drying time of cleaning solution. I used some fast dry panel wipe (for degreasing in between layers of paint) to clean my wiring loom connectors. I thought at the time I might use it to clean the components on my next engine rebuild. These days I expect it’s not to more expensive than petrol? Jon So Trichloroethylene is a no no? Best degreaser that we used to have before we knew what the consequences were  |
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Post by jon on Jul 1, 2022 19:27:06 GMT 1
Money no object I’d go the other way regarding drying time of cleaning solution. I used some fast dry panel wipe (for degreasing in between layers of paint) to clean my wiring loom connectors. I thought at the time I might use it to clean the components on my next engine rebuild. These days I expect it’s not to more expensive than petrol? Jon So Trichloroethylene is a no no? Best degreaser that we used to have before we knew what the consequences were PPE is you friend. Would you drive without a seat belt? Jon |
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Post by chrisg on Jul 2, 2022 11:29:34 GMT 1
So Trichloroethylene is a no no? Best degreaser that we used to have before we knew what the consequences were  PPE is you friend. Would you drive without a seat belt? Jon Ignorance is bliss when your 17  When your told by older, experienced fitters that is ok to use the cleaner that takes your breath away is ok, you tend to believe them .  |
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Post by yamark on Jul 3, 2022 19:08:52 GMT 1
Great gearchange mods Dusty. This thread is like the LC engine rebuild bible Great work mate |
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Post by dusty350 on Jul 6, 2022 22:09:20 GMT 1
Cheers Mark Current Fowlers prices for gearbox bearings; 93305 20502 - £55.20 93311 22027 - £22.98 93311 42045 - £21.10 93306 30504 - £26.46 Large circlip - 93440 52009 - £4.54 Other bearings can be sourced, so it's worth shopping around and looking for alternatives. I got the same bearings for the 400e build and it was virtually half the cost of these, but that supplier isn't listing them now. The spring for the shift shaft arrived;  20220706_195425 by dusty miller, on Flickr £4.00. The original had 2 grooves worn into it where it sat against the cam bolt so I changed it so I could get an accurate adjustment. The cam bolt can get a wear groove too, so I change it as a matter of course. In reality it may not affect adjustment, but a few extra quid isn't gonna make a difference at this point ! With the spring fitted, you can slide the gearshaft into the cases. You can see how the new spring sits over the adjuster cam bolt;  20220706_200819 by dusty miller, on Flickr  20220706_200831 by dusty miller, on Flickr You can now adjust the cam bolt to get the pawls equal distance from the pins on the selector drum. Turning the bolt will move the pawls, an once happy they look the same, you can tighten the nut on the cam bolt whilst holding the bolt with a screwdriver so it doesn't move;  20220706_200838 by dusty miller, on Flickr  20220706_200851 by dusty miller, on Flickr Once happy, you can fold the tab over on the washer behind the nut to stop it moving in use. Dusty |
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Post by chrisg on Jul 7, 2022 6:35:15 GMT 1
Detailed, concise and brilliant pics. Keep up the good work. |
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Post by dusty350 on Jul 7, 2022 7:02:22 GMT 1
Thanks Spin the engine around now to fit the gearshaft oil seal. A bit of tape on the splines protects the seal lip from damage, and some red rubber grease makes it easier to slide the seal into place;  20220706_203333 by dusty miller, on Flickr  20220706_202525 by dusty miller, on Flickr Seal is £11.83 currently. I use an ali spacer that is the same diameter as the seal, and fits over the shaft to push the seal evenly into place;  20220706_204014 by dusty miller, on Flickr Next, I fit the new circlip to the gearbox bearing;  20220706_204402 by dusty miller, on Flickr I coat the new bearings with fresh light gear oil, and fit them to the main shaft, which I have cleaned, checked and oiled. The gear cluster can now be dropped into place in the bottom case;  20220706_205051 by dusty miller, on Flickr Note the smaller bearing on the right in the pic has a circlip groove, but there is no circlip here, so dont worry that you might have lost something !! Dusty |
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Post by JonW on Jul 8, 2022 7:01:04 GMT 1
Im wondering where the poll is to link this as a contender for 'Best Thread Ever'?
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Post by abar121 on Jul 8, 2022 20:12:39 GMT 1
Excellent work Dusty! I'll be referring to this thread like a bible.
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It really was weak.
