The plan was to install the engine in the frame without its heavy bits to make the process easier for the two old dudes performing the task. The primary was rebuilt with its new parts staged on the bench ready to go including a large zip tie fed into its cavity to pull the alternator wires out. This makes a tough job relatively easy. It's time to start staging and assembling the engine's timing and transmission components. The oil pump and timing gears will be installed but the pump itself will go on later.
Timing bits prepped and ready to assemble. The new SRM oil pump is a real beauty.
I hope it works as good as it looks. What a shame to hide it behind a cover.
The transmission bearings and seals were renewed even though they didn't look bad. The layshaft end play was checked by installing the mainshaft in the case and measuring to the workshop manual specs. A play of .002 was measured and will get that "butter smooth" BSA shifting I admire. The selector plate had very little wear on it and was reused with minimal cleanup. One shifter fork was worn and both were replaced as were the kickstart pinion gear and bushing.
Worn and replaced.
New bearings, seals, shifter forks and kicker bits. Oiled and ready to assemble.
Transmission bits assembled and ready to install
The last order of business on this side of the egg was to mount the kickstart spindle and its washer/spring from hell combo. I have fought this in the past but not as hard as on this one. A stiffer spring than others, I'm getting older and weaker, maybe my biorhythms were off??? Not sure but I stuck with it and was victorious. There is probably a factory tool I will never own to simplify this task. There has to be, otherwise I would call it a piss poor bit of engineering from a home mechanics perspective at least. Too bad I don't drink beer anymore. This would be a perfect time for one or six.
What a bugger of a job....until I figured out how to do it then it was a moderately difficult task. I'm putting a picture of my process here so I can reference it next time.....Push the washer on over the spring, put a hose clamp on the shaft to hold the washer in place and then pull the spring on with a hook tool all while trying not to impale yourself. The wrench was used to work the washer tab toward the spring hook.
The '64 LR speedo drive is off of a gear mounted on the layshaft. Interesting. There are a series of gears you can swap to calibrate the speedo if you make drivetrain changes. There is also a badge on the outside of the case that denotes the installed speedo gear's ratio.
Getting ready to assemble and prime the new SRM oil pump. Good lord that herringbone oil line is hard to find and expensive when you do.....
Turning stainless steel into CAD ....kinda....
Oil pump assembled and primed with oil running out the PRV mount per SRM's instructions. A final check will be completed before starting the engine by pushing the bike down the road in gear with no spark plugs. Oil will flow into the tank through the return line if all is right .
The SRM pump was very stubborn and did not prime easily. I turned over the rear wheel in 4th gear while my wife added pressure to the oil tank via my trusty propane air tank. 15 PSI did the job.
Assembled and ready for the Trispark unit.....onto the ignition.
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