And Then It Starts

[headcoats]

Just got my barrels back from Martin Johnson, so can start putting the engine back together on Yellow Kenny which originally had the Athena barrels.

The reason it's all back in bits was a noise it developed which to me sounded like it was around the right side ,somewhere by the kick start mechanism ish !
Changed the kick start mechanism for another ,changed primary gears (twice),idler gear was brand new,all koyo bearings in gear clusters,crank from PJ engineering with 600 miles on it now.

Thought I had it with the mechanical speedo gears but removed the top bit that the cable runs in but not that.
Don't know what else to check but if I put it back together and get same noise, I will need Therapy 🤣

[headcoats]

Engine is completely stripped at the moment ...

[JonW]

whats the idler's deflection like on the shaft? I assume new washer and lock? Reason I ask is that they can wear the shaft so that while a new one is better, it doesnt always fix the tapping.

[headcoats]

There is some play still I Don't know what is acceptable but if I waggled it about it wasn't hitting the primary gear.

I do have a couple gear clusters so could try them and see if I get same movement.

I am convinced the noise is in this area

[JonW]

There is 'some play' but if its not hitting and the play is minimal then its probably ok.

You can also usually see some witness marks on the basket gear, but if thats happened before (ie most bikes) then looking wont help :/

[headcoats]

It's doing my pea brain in 🧠
Can't see anything catching or witness mark

P.s.
Thanks for answering as everyone else is swerving it LOL

[JonW]

haha, i expect they are scratching their heads and thinking while i blabber on... HAHA!

Good luck in the search, I cant think of anything else right now... you could drive the tacho drive (drill on the cable) when the gear isnt connected and see if that makes a noise? try both ways of course.

[headcoats]

Yes good idea
I did take the top gear out but the other gears would have still been spinning.

All the primary gears I used all had correct backlash number.
Water pump bearing was new with genuine seal etc
No chips in gears ,selector forks hardly marked
There isn't alot in there

Bet Michael Dunlop and his team would find it 🤣

[JonW]

Nah. He'd just ride around the issue

[headcoats]

What am I looking for in the following for defects/wear

Kickstart mechanism

Gears

Mechanical tacho gears

Primary gears

[headcoats]

Growing a beard here 💀

[muttsnuts]

several things to check, some mentioned above, the weirdest one I've had is the tacho drive causing a "ticking" noise (sounded like a little end going), it turned out because the drive is helical to the tacho cable drive gear, the shaft was "floating" in and out of the crankcase and tapping the retainer plate holding the shaft etc in place (the holder had some wear on it). I removed the plastic drive gear and the noise disappeared, I fitted it back and it came back, odd, but true !

[headcoats]

It could just be that Dave but is only replacement of the tacho gears a cure ?

When you day shaft,is that the main one holding the plastic gear,not the little gear that goes in the top ?

[muttsnuts]

yes the main shaft that the gear goes on

I am not certain what it is, all I know is when I removed the plastic gear the noise went, put it back on and it came back. Until I get the engine stripped I won't know and given its the only bike I have on the road, it might be a while before I strip it to find out what is causing the noise !

[headcoats]

Slowly putting the gremlin filled engine back together and just looking at water pump impeller.

Is there supposed to be a bit of "in and out" movement 🤔

Also the large washer that goes on the top of the white plastic gear looks shiny and when circlip is on the washer rattles?

Chasing my tail here but just want to rule stuff out