A65 Lightning project......

[ChrisG]

The two sprockets recommended for A65 solo's were 20T or 21T. Its a personal choice but I found on an early Thunderbolt I had that the 21T was still too low gearing wise and felt revved out at 55-65MPH. On the OIF one I had, it was fitted with a 22T and that was much more comfortable. (SRM make these but you need to file some of the slots in the rear of the chaincase to get it through or take the gear cluster out to slide it in).
As it will be a Lightning Clubman, it maybe acceleration you are looking for so I would suggest you try it with the 21T you have and if you're happy, change it for a new one. If not, go up or down to suit.

[geraldhattrick75]

That's brilliant....

I'll go for the  same as is then and purchase a 21t jobbie.

Thanks very much for that.

Regards,
Dave.

[Splodger]

If your drive sprocket is hooked and a replacement is to be fitted, you'll want a new chain as well - assuming, also, that the rear wheel sprocket is not overly worn?

Regards,

Splodger

[geraldhattrick75]

I should have mentioned Splodger, that I have a brand new rear sprocket included with the ods-n-sods and I intend on buying a brand new chain...... But that's a long way off. Thanks for your helpful suggestion though.

At the moment I'm concentrating on the bottom end and today's query is, having loosely fitted the timing side middle cover, I have a nicely machined shaft (3 3/4 x 3/8) and I can't see anywhere that it might fit on the timing side.

The haynes manual was absolutely no help and the helpful parts list diagram doesn't show such a shaft. (it does look a bit like the gearbox fork selector shaft- but I haven' touched the gearbox so it can't be that)

Any suggestions would be highly appreciated.

Thanks,
Dave.

[ChrisG]

Could be the Kickstart Quadrant peg that fits in a hole very near the rear of the inner timing cover. Most stay put but some like the one on my Royal Star do drop out.

[DerekAnderson8]

it looks like the shaft for the primary chain tensioner.

[geraldhattrick75]

A ceegar for Derek. It was the drive side, primary chain tensioner pivot...... (I wasn't as careful as I thought when I put the parts in marked boxes )


Re the kickstart quadrant peg, it stayed in place.....

Thanks for your help guys.

[JOHN KAY]

 HI DAVE
JUST A THOUGHT > I USED TO HAVE AN A65 1965 LIGHTNING WITH DC ENGINE NUMBER >
I BELIEVE THE C STANDS FOR CLOSE RATIO GEARBOX FITTED > I WOULD COUNT THE NUMBER
OF GEAR TEETH TO COMPARE WITH STANDARD RATIOS . MY BIKE HAD UNUSUALLY CLOSE RATIO
1ST 2ND AND THIRD GEARS WHICH I BELIEVE COULD BE FROM 1967 BIKE ( THIRD GEAR )
BEST TO CHECK PARTS BOOKS  FOR GEAR TEETH NOS .  ALSO MINE HAD DIFFERENT COLOUR
PAINTED DOTS ON THEM TO IDENTIFY THEM IF MEMORY SERVES . ALL THE BEST REGARDING YOUR
PROJECT REGARDS JOHNBOY .

[geraldhattrick75]

Thanks Johnboy, I'll look at how many times the output gear shaft turns for every rotation of the engine once I get the primary side sorted. (21 tooth sprocket came today...)

I know I'm going to regret it later but, as the gear selector seemed ok and the shaft rotated nicely, I didn't strip the box, so I haven't identified gear markings.


Incidentally, how can you tell if the triplex primary chain is worn? (there's no sideways or twisting movements in the chain, but then it is a bit of a beast- especially when compared with the Velo Venom primary jobbie...

Out of interest, what do you reckon the badly welded lump is on the timing case- just below the contact breaker position? (My money is on some sort of oilway put in by the factory while they were experimenting)


Again folks, thanks very much for your help.

[ChrisG]

Assuming the badly welded lump is on the outer face of the inner timing cover it would be the oilway to the end feed big end lubrication on the SRM or previously Devimead conversion. The oil comes out of a hole in the crankcase with an O ring groove around it, perilously close to a screw hole and connects with similar in the inner timing cover (inner face). Out then comes out via the oil seal at crankshaft position which fits nicely over the quill.

[geraldhattrick75]

Assuming the badly welded lump is on the outer face of the inner timing cover

That's exactly right..... But I couldn't see the quill, nor an o- ring, although I do see, from my photos, where an o- ring might be supposed to fit..... Which is a bit of a bummer given that I have now fitted the inner timing cover and set up the ignition timing.....

What's even more frustrating is that I cant find any photographs of the inside of my inner timing case to corroborate the process.

Looks like I might need to take the cover off again..... (don't want to prevent lubrication getting to the big ends)

Permission to say 'bugger' sir?....

[geraldhattrick75]

I've not yet removed the inner cover but before I do I thought I'd check: the parts book, the Haynes manual and the on-line 'shop manual' and none of them mention an 'O' ring or quill.

Bearing in mind my propensity for cocking things up and misunderstanding what I am being told, should there be any sort of small 'O' ring between the inner timing case and the crankcase?

I'd just like to confirm what I will be looking for if I take the inner timing cover off....

Thanks again for your help,
Dave.

[JulianS]

Your end feed mod will not be in the Haynes book.

The original setup fed oil to the big ends via the plain main bearing bush.

The end fed bike crank is modified to fit the quill and oil fed to big end via quill and modified oilways and oil seal in the cover.

I think you need to remove the covers to be sure of what you have.

[geraldhattrick75]

I'm waiting for a reply that says "leave it as it is Dave"........

But deep down I know you are right...

Oh well- off to the garage. (it'll be your fault if I get pneumonia...)

I'll report back with piccies....


Thanks for your advice,
Dave.

[geraldhattrick75]

Right, having stripped it down you are, of course, spot on- it makes sense now that I know what I'm looking for.

I'm guessing that this engine was one of the early experimental jobbies. Hence the untidy nature of the work.

Fist picture shows the oilway hole that should have had an 'O'-ring. (and as I'd assembled it)
Second picture shows the 'O'-ring in place. (and as I should have fitted it when assembling the case)
Picture three shows the seal (dowty washer?) that fits over the 'quill' feeding (or returning from) the timing side main bearing.
Picture four shows the quill that fits into the dowty washer(?)/ main bearing.

Does that sound about right?


Oh, and many thanks for your persistence....
Dave