Mostly M21 Notes ---------------- 1948 Telescopic forks replace Girder forks 1950 New gearbox and clutch 1951 Start using Alloy cylinder head 1951 Start using plunger rear wheel 1955 End of the M20 1958 M21 becomes "special order" 1963 End of the M21 Engine & Frame Markings ----------------------- 1949 to 1952 1953 to 1957 --------------------------------- --------------------------------- Model Engine Rigid Frame Spring Frame Engine Rigid Frame Spring Frame ----- ------ ----------- ------------ ------ ----------- ------------ M20 ZM20 ZM20 ZM20S BM20 BM20 BM20S M21 ZM21 ZM20 ZM20S BM21 BM20 BM20S Pittsburgh PA M21 Owner's name is David Matthias 922 Clyde St ext Wampum PA 16157 Home 724-535-1155 Work 800-876-3211 x294 Missing or incorrect gas tank and finders Transmission was partially disassembled (cover removed) to install new kick start paws. These new parts are with the bike. The front forks are not original to the bike. It now has A65 forks or some similar BSA forks. It has the oil tank. History It was running, then modified (tank, finders, forks), then disassembled to repair the transmission, and never ridden again. Is it a plunger frame ? No I double it. It has an 18" rear wheel which is probably original. Serial Numbers: Frame BM20 9359 Engine BM21 10403 The title is for 1957 Liberty Moving 800-640-4487 x216 Michel Pittsburgh to Lansing is basic $264 plus $60 for each end that is not a commercial address. From when you finalize the order for the move they then want 3 working days for the pickup. They then want 5-13 days to deliver it. Must drain the gas from the tank. \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ David Matthias 1-JULY-1999 922 Clyde Street ext Wampum, PA 16157 Hi Dave, Enclosed is the payment for the M21 motorcycle. Thank you for taking care of getting it ready to ship. I hope that with the transmission cover back on and the rest of the parts in a box that is taped into the frame somewhere it should all make it here OK. When you call to let me know that you have the payment OK and that I should arrange for the shipping will you let me know if the bike is being picked up from a "commercial address" or a "residentual address". The pickup charge is less if it is from a commercial address. I guess that they assume it is easier to get a truck to a commercial address. The plan for the bike is to slowly move it back to a more or less original condition. I was hoping to find one with a plunger frame but nothing has shown up so far. I have no idea how many of these things were made made, I never have seen one on the road. Thanks again for getting it ready to ship. Dan Dan Edmunds 231 Durand St East Lansing, MI 48823 phone: 517-332-0622 \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ Wednesday 7-JULY-1999 afternoon David Matthias calls and talks with Carol. He got the check, wants 5 days for clearance, and then will call back. Friday 9-JULY-1999 Order 2 M20-M21 books: BSA M20 & M21 Super Profile Series Owen Wright Merlin Books Haynes Pre-Unit Singles J C Whitney \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ A random reference says that the Lucas Magneto capacitor is 0.2 uFd 400 Volt \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ Thur 15-JULY-199 Dan--Today is Thursday and there was a message on the machine about your new motorcycle. The message was a bit warbled because he apparently talked before the beep, but what I could get was that your check has cleared and he is anxious to get things rolling. He asks that you call him Friday, I assume during the day at 1-800 876-3211 extension 294 the instructions are to ask for Dave. See you tomorrow night. Carol Friday 16-JULY-199 Talked to him on the phone Friday morning. The beginning of next week is an OK time for them to pick it up. He now has a gas tank for it. His company is called "Modified Motors" and is mostly an HD salvage business. He has a "business license" so it is a commercial address. Called Liberty Moving on Friday morning. Need to call them on Monday to get them to FAX me the papers for payment. Sunday night 18-JULY-1999 David calls to say that he has not heard from the moving company yet (but I did not expect that he would have). Loading it the next Monday, i.e. the 26th, is convenient for him. Wednesday 21-JULY-1999 fax the card payment papers to Liberty and Michelle says that everything is all set. The shipment registration number is: 721574. Thur 29-July-1999 Mark at Tanterra Corp calls. They are ready to deliver Friday Morning. 800-356-1900 ext 270 Fri 30-July-1999 They deliver it. A thing on two wheels, three cardboard boxes, and a gas tank. 16-AUG-1999 It has a 20 tooth engine sprocket, i.e. a solo setup. Front Wheel is 3.25 x 19" Rear Wheel is 3.50 x 19" B25 valve cover Est. Part No qty Price ------- --- ----- Seat 1 Headlight Housing 1 Chain Guard 1 Handle Bars 1 Primary Chain 24-8930 1 39.19 Rear Chain 24-8713 1 45.00 Rear Stand 66-4772 1 Y_DF Footrest Rubber 29-7551 2 Y_DF Carrier Complete 66-6979 1 Y_DF Footrest spacer between plates ? Ref B.O. a.m. Gearbox Parts Desg Part No qty Price Price -------------------------------------- ---- ------- --- ----- ----- Nut for Gearbox Connecting Bolt 78 02-0046 2 3.44 A.M. 01-000003 3/8 x 26 Nut 1.08 Washer for Gearbox Connecting Bolt 79 66-4707 2 0.25 A.M. 3/8 shakeproff washer 01-014119 0.39 Serrated Washer Gearbox Connecting Bolt 80 65-4189 2 not 5.13 81 66-4169 1 Gearbox Adjusting Nut 102 15-5664 1 4.88 6.19 Gearbox Adjusting Bolt 104 27-5710 1 Y_DF 1.35 Gearbox Connecting Bolt Rear 105 66-4168 1 5.90 4.05 Gearbox Connecting Bolt Front 107 15-0476 1 15.54 - Kickstarter Ratchet Pinion Sleeve 121 66-3081 1 21.99 15.12 Kickstarter Ratchet Spring 122 24-4256 1 3.49 2.17 Kickstarter Ratchet Pinion Sleeve Nut 123 24-4282 1 Y_DF 4.05 Kickstarter Ratchet Pinion Lock Washer 124 24-4278 1 Y_DF - Kickstarter Ratchet Pinion Slv Locknut 125 24-4255 1 not 5.41 A.M. catalog indicates that these Nuts are 9/16 x 20 Gear Operating Lever Nut 115 2-1813 1 0.94 3/8CEIx26 Half Plain A.M. 01-000073 3/8 x 26 thin 1.15 Gear Operating Lever Locking Washer 116 15-4232 1 Y_DF - Pawl Carrier Arm Bottom complete 33 15-4243 1 Y_DF Pawl Carrier Arm Top complete 34 15-4242 1 Y_DF 8.12 Gearbox Inspection Cover Screw 7 27-4258 1 3.59 - Gearbox Operating Shaft Clip Ring 130 15-4240 1 2.04 - Gearbox Gear Control Link Pin 44 15-4221 1 Y_DF - Gearbox Oil Seal 9 65-3508 1 9.96 10.07 Gearbox Inspection Cover Gasket 6 15-4110 2 0.64 0.80 Gear Operating Fork 14 66-3290 1 64.68 16.25 Pawl Carrier Arm Main Spring 31 15-4139 1 6.09 2.17 Pawl Return Spring 35 15-4161 1 6.09 2.17 Clutch Push Rod Adjusting Screw 49 65-3403 1 4.00 5.80 Operating Pedal Spindle Rubber 57 29-3250 1 3.09 2.42 Kickstarter Crank Rubber 59 65-3212 1 - - Kickstarter Crank 62 15-4179 1 - 36. Kickstarter Crank Cotter Pin Nut 65 2-2578 1 A.M. 57-2706 0.42 Kickstarter Crank Cotter Pin Washer 66 15-5155 1 0.36 A.M. 82-8981 0.26 Kickstarter Crank Cotter Pin 67 2-2579 1 A.M. 57-4356 3.24 Kickstarter Crank Spring 72 66-3058 1 29.95 18.80 Kickstarter Return Stop Rubber 75 66-3259 1 Y_DF - Outer Cover Joint Gasket 68 66-3131 1 1.37 1.62 Gearbox Inner Cover Ball Bearing 77 24-4217 1 32.20 A.M. 49-00048 25.85 Gearbox Drain Plug 99 28-0043 1 - 4.35 Gearbox Dog Clutch 102 24-4393 1 9.86 10.83 Inner Cover Joint Gasket 109 66-3069 1 1.23 1.45 Speedometer Bush Retaining Pin 112 65-3400 1 3.51 2.42 Ref B.O. A.M. Clutch Parts Desg Part No qty Price Price -------------------------------------- ---- ------- --- ----- ----- Chaincase Sliding Plate 66-7520 1 24.57 26.78 66-7520 23.09 BCS Mainshaft Nut 66-3787 1 15.39 28.31 Mainshaft Nut Locking Washer 65-3822 1 1.52 2.42 Clutch Ball Race Ring Inner 65-3911 1 21.18 35.69 Clutch Ball Race Retaining Ring (Bearing) 65-3910 2 7.77 12.71 Clutch Ball Race Ring 65-3912 1 16.08 12.10 Clutch Chainwheel complete 66-3908 1 126.55 British Cycle Supply says that 42.3223 131.14 42-3223 will also work 42-3223 1 96.30 BCS Clutch Sleeve 65-3873 1 87.41 A.M. says 42-3107 is the same 54.87 Clutch Sleeve Collar 65-3833 1 21.82 24.99 Gearbox and Chaincase Oil Retaining Washer 66-3090 1 2.00 1.35 Gearbox Felt Washer 24-4232 1 0.73 - Clutch Driving Plate with Inserts 65-3857 ? 10.52 16.90 British Cycle Supply says that 7.72 42-3119 & 65-3825 will also work 42-3119 13.02 BCS Clutch Driven Plate 65-3824 ? 8.79 14.19 4.72 Clutch Sleeve Plate 65-3872 1 27.98 12.18 Clutch Spring Retaining Nut 1/4 x26 CEI 2-2395 2 0.50 A.M. says use 01-000005 0.62 Est. Control Cable Parts Part No qty Price ----------------------------------------- ------- --- ----- Throttle Cable Air Slide Cable Front Break Cable Clutch Cable Ignition Timing Cable Est. Control Cable Parts Part No qty Price ----------------------------------------- ------- --- ----- Rear Chain Adjuster Screw 66-4620 1 not Rear Chain Adjuster Screw Locknut 27-4401 1 2.62 Oil Tank Mounting Screw 5/16 x26 CEI x1.109 15-0480 3 5.92 5/16 x26 CEI x 1-3/16 2-6026 3 3.58 Battery Bracket to Frame Stud 65-5327 2 3.37 Battery Bracket to Frame Stud Washer 36-0382 2 0.36 Battery Bracket to Frame Stud Nut 5/16x26CEI 24-0563 2 0.73 Pertol Tank Rear Fixing Bolt 65-8034 2 Y_DF Pertol Tank Rear Fixing Bolt Washer 30-0660 2 not Petrol Tank Rear Support Bolt Rubber Bottom 65-8032 2 2.25 Petrol Tank Rear Support Bolt Rubber Top 66-8091 2 Y_DF Petrol Tank Support Sleeve 27-8447 2 Y_DF Petrol Tank Front Support Rubber 27-8448 2 Y_DF Petrol Tank Front Support Rubber Cap 27-8449 2 Y_DF Petrol Tank Fixing Bolt Front 5/16CEIx26x23/32 28-2338 2 2.40 Engine to Engine Plate Bolt Nuts and Lock Washers \|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/- Part Number Location in the British Only OnLine Catalog the 02- part numbers are in section #1 the 15- part numbers are in section #2 the 24- part numbers are in section #5 most of the 65&66- part numbers are in section #19 \|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/- 6-SEPT-1999 Rear Through Bolt Spacer Layout Timing Side Spacer 1 9/16 Engine Plate Spacer 2 1/2 Engine Plate Spacer 1 13/16 Rear Break Plate Control Arm Drive Chain Side Seat Dimensions: Horizontal lenght nose to center of springs 9 1/2" Vertical drop to spring mounts 6 " Diagonal lenght nose to spring mounts 12 1/4" Nose mounting tube length 1 3/4" Distance between spring mounts 8 1/2" Thickness of the paper casket between the transmission main gear case and the tranmission inner cover is about 6 mils. Diameter of the tubes that make up the front section of the frame Down Tube 1 1/2 Front Horz Tube 1 1/2 Seat Tube 1 3/8 In places the tubes appear about 5 to 10 mil over size (because of paint ?) 4-OCT-1999 Order from British Cycle Supply @ 902-542-7478 Wayne 61-1903 222-108 $10.27 61-3362 222-117 $11.46 Become customer number E880 Parts to "De - Chrome" Front Fender 1x Primary Cover 1x Front and Rear Wheel Rims 2x Oil Tank 1x Brake Peddle 1x Rear Brake Plate Control Arm 1x Foot Pegs 2x Foot Peg Through Bolt 1x Foot Peg Mounting Sleave Nearside 1x Front Fender Stays 4x Front Frame Cover Plate 1x Battery Holder 1x Headlight Mounting Brackets 2x Tail Pipe and Muffler Mounting Brackets ?x Brake Peddle Mounting Bracket and Spring ? 2x Rear Brake Actuating Arm ? 1x Rear Brake Rod and Nut ? 2x Brake Light Switch and its Bracket ? 2x Dynomo and Magneto Connection Covers ? 2x Lucas Magneto Model: M01L Primary Resistance is about 0.49 Ohms Secondary Resistance is about 4,070 Ohms Primary side with the strap going towards the center of the hub is at Gnd. Both contact side terminal mounting screws are at Gnd. Viewing the magneto drive shaft in front of you it turns CCW. The outside diameter of the outer race on the points end of the magneto is about 1.377" which looks like 35 mm. Some Bearing Measurements O.D. I.D. Thickness Condition ------- ------- --------- --------- Dynamo drive end 1.378 0.590 0.433 poor Dynamo brush end 0.866 0.315 0.276 poor Transmission small 1.875 0.750 0.561 poor Transmission large 2.836 1.377 0.669 good outer race inner race ------------ ------------ Dynamo Drive end HOFFMANN 115 V2 115 V2 G Dynamo Brush end HOFFMANN SRQ NFY 108 V2 G Transmission small HOFFMANN L8 V2 X TSR LS8 V2 (or L58 V2) Transmission large HOFFMANN 135 V2 TSRQ 135 V2 Hoffmann Commercial Number Number ----------- ---------- Dynamo Drive end HOFFMANN 115 V2 6202 about $5.00 ea Dynamo Brush end HOFFMANN 108 V2 608 about $5.17 ea Transmission small HOFFMANN LS8 V2 - Transmission large HOFFMANN 135 V2 6207 about $11.09 ea Ok the previous experience getting Hoffmann bearings for the Triumph engine is as follows. Needed a Hoffmann LS-7 for the small end of the transmission. What I got from Invetech (Detroit Ball Bearing) in a plain generic box labeled "BEARINGS" with a sticker printed "NORMA LS-7" is a bearing that has printed on its inner race "NORMA HOFFMANN LS-7 MADE IN USA". It is in an un-sealed plastic sack in the box. I have no idea how long ago the bearing was made. It cost $6.38 each plus $10 for freight for getting two bearings on 18-JAN-96 and the contemporary cost for this bearing from British Only was $???. On the invoice it is written as LJ-5/8 NORMA SKU Code 960900000. Note that the ID of the inner race of the LS-7 is 0.625". It looks like Invetech (Detroit Ball Bearing) is now called Applied Industrial Technology (Detroit Ball Bearing) still at 4302 Creyts phone 322-2010. Purchase new bearings for the Dynamo SKF 608 2RSJEM with seals $7.90 SKF 6202 2RSJEM with seals $5.91 Dynamo Rebuild Issues --------------------- The end of the outer case with the lettering on it is the drive end. The end of the removable pole shoe with the 4 narrow stripes goes towards the brush end of the dynamo (i.e. the end of the field coil with the connecting wires. The end of the pole shoe with the one think line and the one narrow line goes towards the drive end of the outer case The clothe tape on the field coil winding had some rust embeded in it. The splices between the connecting wires and the winding of the filed coil are on the long sides of the coil, not at the brush end of the coil. The screws holding the pole shoe to the outer case must be something like 5/16 x 22, i.e. not a standard inch size thread. What the Dynamo says on it is: LUCAS, MADE IN ENGLAND, E3LM-L-O , "Y" with a circle around it then 20034B, 6V >>--> 2 57 Careful 2 lead measurement of the field coil resistance gives 2.62 Ohms. The book says that the field coil is 2.8 Ohms and that it draws 2.1 Amps when connected across a 6 Volt battery (which clearly is not consistent). Replaced the two ball bearings with new sealed units (see the bearing section). When re-assembling the dynamo it appears that the shaft may have moved in the armature plate commutator assembly. It may have moved when the drive end bearing was being installed. It looks like it may have been pushed back about 1mm i.e. the armature plate commutator assembly moved towards the drive end about 1 mm. Initial tests of the Dynamo It will not start up when running on the lath 2 Amps in the field from an external source and spinning at 620 RPM gives only 4.2 Volts open circuit from the armature. Try checking the armature to see if it looks the same in all positions Put a 3 Amp current through it and measure the voltage across it. Make 2 full rotations plus the start of a 3rd. Note there should be a two fold symmetry: Volts Across Armature -------------------------- Position 1st 2nd 3rd -------- ---- ---- ---- 1 2.1? 2.10 1.90 2 2.1? 1.91 3 2.1? 1.91 4 1.97 2.07 5 2.11 1.96 6 2.29 1.93 7 1.94 1.92 8 2.28 1.94 9 2.25 2.08 10 1.85 1.87 11 1.88 1.92 12 1.95 1.87 So all this implies that the armature and commutator has a resistance of about 2/3 Ohm. So to get 10 Amps out of this will take about 6.7 Volts just to overcome the internal resistance of the armature and commutator. Test running the dynamo at a little higher RPM than the 620 available on the lath makes it build up to 10 Volts or more with no problem. It was running at perhaps 1000 RPM. Dynamo Lucas Part Numbers: -------------------------- Dynamo complete 20034A Brushes set 200737 $ 13.99 AM Spring set brush tension 220197 $ 1.85 AM Grommet cable 200895 $ 2.65 AM Armature 200754 $228.92 AM Field Coil 200731 x Sundry parts set 200806 x (includes the screws to hold the pole piece shoe) Magneto Part Numbers: --------------------- Magneto complete 464247 x Strap securing generator 460056 $ 28.66 AM Bush generator securing strap 460055 $ 3.23 AM Pickup (housing or complete?) 463066 $ 17.34 AM Pickup Brush and Spring 451260 $ 48.66 AM Contact breaker (complete?) 460051 $ 46.18 AM Contact set 484098 $ 11.49 AM Tappet 464092 $ 3.93 AM Control set (complete?) 463107 $ 27.75 AM Cover control rubber 454475 $ 2.14 AM (use 95 57-1646) Nipple control cable 455788 $ 0.71 AM Pin & spring securing CB cover 463899 $ x AM Brush and spring earthing 455190 $ 2.77 AM Armature 464205 $ x AM Slip ring 454496 $ 36.60 AM bolt through fixing 101270 $ x AM Condenser 454415 $ x AM Thrower oil 463944 $ 2.07 AM Washer oil thrower (linen) 164334 $ 0.55 AM Collar spacing 455634 $ 1.00 AM Engine Disassembly ------------------ Yellow dot on Magdyno idler gear faces out. The side of the piston with the circlip pulled out (also the side labeled 66-1039) goes on the drive output side of the motor. The scavanger pump gear with the cicular scratches is the driven gear. The diameter of the shaft on the drive output side of the motor appears to be 25 mm Mark the inside edge of the outer races of the crankshaft bearings with a mark on what was the bottom before they were removed. Drive side Ball: Hoffmann 125 OD = 2.047" i.e. 52 mm looks like a ID = 0.984" i.e. 25 mm 6205 bearing Thick = 0.591 i.e. 15 mm Drive side roller: Outer Race Hoffmann R325L OD = 2.441 i.e. 62 mm ID = 2.128 i.e. 54 mm Thick = 0.669 i.e. 17 mm Inner Race Timing side OD = 2.250" ID = 0.875" Thick = about 0.700" Microstation Drawing of the Frame --------------------------------- Level 2 is the drawing, Level 3 is the image reference file, Level 4 is construction lines, Level 5 is the whitness lines, Level 6 is the dimension text, Level 7 is the center lines The estimated scale is approximately 1" on the drwaing is 10" on the real frame. A possibly more accurate estimate of the scale is 1" on the drawing is 9.994" on the frame. List of what was not very well understandable from the scan of the copy of the copy of the original of the drawing: Do the right hand and top dimensions apply to the boss on the stearing head or to the point where the center linds of the stearing head tube and front down tube cross. Does the dimention run through, and refer to the center of the front side car mounting point just below the stearing head. GEARS ----- Timing Crankshaft Pinion 18 T Camshaft Pinions 36 T Idler Gear 60 T Magneto Pinion 36 T Magneto Fabric Gear 58 T Dynamo Pinion 22 T So the Dynamo runs at 1.318 (29/22) times the engine crankshaft speed. Transmission ReBuild Winter 1999-2000 Frame returned from Vern Fueston Saturday 6-MAY-2000 Re-Assemble the clutch friction plates May 2000. The friction inserts varied from 152 mils to 167 mils thick. Most of them were in the 154 to 164 mil range. They were sorted into 1 mil increment piles and from those they were then arranged: thickest, nt thickest, nt thinest, thinest. Each of these 4 groups was used to load one clutch friction disk. The friction pads for a given disk were randomized and then every other one was insterted from the oposite side in an attempt to keep the metal disk in the center of the assembly. The metal disks appear to be in the 95 to 98 mil thick range. The 4 new "non friction" plates that I got from Dragandfly have a manufactures stamp "Sureflex". I will most likely instert the best one of the old non-friction plates between the outer pressure plate and the first friction plate. This is because the outer pressure plate has some pits in its surface that works against the friction plate. Ron Richards friend who does very old car repair is named Dan Shafarman 487-6534 at 310 Charles West side North of the bar One Michigan magneto repair place is: 8924 Linda Ray Lane, Gregory, MI Exhaust System -------------- The exhaust pipe that came with the M21 is 1 3/4" O.D. From the two pictures in the Super Profile Series book it appears that the muffler is 19.5" long and 3.5" in diameter. The length includes the domed ends. The recess in the gas tank for badges is 3 5/16" to 3 1/2" ID-OD diameter. The rear fender stays with the lift handle has a 6" opening where the fender goes. The good brake leaver is complete except for the horizontal clamp. Need a clutch lever. The rear fender on the B25 is 5 3/4" wide Fork Issues ----------- The front fork assembly that came on the M21 bike is not from a M21. The crown of the yoke has a part number 68-5049 which means that the fork assembly is from a 1962-1965 A50 or A65. Measuring the inner tubes their O.D. where the slider bushes run is 1.249" where the lower yoke clamp goes is 1.375" and they are about 21 1/8" total length. The length of the area for the lower clamp is 1.25" and the distance from the top of the area for the lower clamp to the top of the tube is 6 3/8". The taper at the top of the rusted inner tubes that came with the M21 are about a 5.94 degree taper. From a point on the taper that is 1.265" dia to a point that is 1.160" dia the run along the edge of the tube is 1.015" The taper at the top of the replacement tube that was originally used on the C25 has a 5.70 degree taper. From a point on the taper that is 1.170" dia to a point that is 1.310" dia the run along the edge of the tube is 1.410" Painting SW Sandblasting 579 Kirkland 243-7550 possible fender 55-10163 High Quality B50 Parts Source: E&V Engineering Howard City Mich phone: 231-937-6515 Carrillo rod. Brazing Rod from Eutectic - Castolin # 1703 49% Ag and includes Ni 680-700 deg C 450-550 MPa # 1800 57% Ag 625-655 deg C 400-500 Mpa #1802 Flux prime with self etching primer Martin Senour 7220 NAPA spray can. --------------------------------------------------------------------------- Jobs List --------- Clean and check threads (and de-chrome) 80 nipples Bend the rear stand arms to parallel Clean the primary cover Clean the Oil Tank Clean and coat the Gas Tank Straighten the front fender mill the fork tubes Front and Rear Wheel Bearings 1x Top tube nut key nipples Transmission shaft nut 9/16 x 20 Rear axil nut Clutch Lever Make a gasket for the Oil Tank: OD = 2.420" ID = 1.920" thickness = 2.2 or 2.3 mm --------------------------------------------------------------------------- The name "Commander" was given by BSA to the M21 single-cylinder side-valve 600cc model about 1956 to help with marketing in the US. The M21 had been the utility model and sidecar hauler for years, since the 30s in one form or another, and survived until 1963. They and their cousin the M20 were the low-end of the spectrum of BSA singles, the high-end of which was represented by the Gold Star models.... Lannis --------------------------------------------------------------------------- Seat Spring Hole Spacing In the Frame: best estimate is 8.807" in the range 8.791" : 8.850" In the Seat: 7.630" 8.622" 9.972" i.e.: 1.177" 0.185" 1.165" too small too small too big New Seat It came from some company called "Tinku Motor Cycle Parts and Accessories". It *might* be Spanish. So far no luck in finding "Tinku". --------------------------------------------------------------------------- Hi all - well have a look at this: http://www.flexi.net.au/~dbrailey/bsa/manuals.html History in the making and you'll never need a parts book again! - well for those early ones! {prices are listed on the page} Contact me (jon-paul.bingham@yale.edu) if you are ordering from USA Contact David Brailey if you are ordering from Asia and Australia (including New Zealand) - e-mail page attacted Contact Ron Farthing in the UK if ordering from UK or Europe Note like David's other books/manuals - these will be limited and a resource always requested for by BSA fans! All the best JP --------------------------------------------------------------------------- 12-JUNE-01 New sealed bearings for the M21 front wheel (standard 8" break front wheel). From Applied Industrial Technologies. They cost $26.72 each. The bearings are SKF part number RLS7-2RS1. These are sealed bearings. They are English measuement size bearings, i.e. not standard stuff. They were made is South Africa. This is I think the same price that Domi Racer wants. RLS7-2RS1 is: OD = 2.000" ID = 0.875" Thickness = 0.565" --------------------------------------------------------------------------- Front Gas Tank Mount Points: The drive chain side has the brass fill. The timing side is all steel. The original size was 3/8 but this was stripped out. Changed to 7/16 x 20 tpi. 20-AUG-01 Receiver the rear fender aka mud guard. The front fork springs that came with the m21 had a YELLOW paint spot at one end. They are between 21 1/3 and 21 1/2 turns full end of wire to end of wire. The rear brake return springs are about 1/2" OD and are about 14 turns. The front brake return springs are about 0.35" OD and are about 15 turns. --------------------------------------------------------------------------- Oil Tannk Cap Oil Seal Outer Diameter 2.450" outer radius 1.225" Width 0.250" inner radius 0.975" Thickness 91 to 98 mil range Front Axil Seals Thickness 91 to 98 mil range Axil Shaft Diameter 0.875" Brake Plate Hub Diameter 1.291" - 1.295" --------------------------------------------------------------------------- ToDo_List Clean up and in most cases Paint: Fork pinch bolts and nuts Fork Springs Grease Fittings Brake Shoe Springs Fork seal holders (dechrome first) Make a felt gasket for the slider in the primary cover. Final clean up and rust proof of front and rear frame sections and the two wheels. Make a pin wrench for the front wheel bearing retainers. Make a gasket for the front wheel bearing retainers. Make a gasket for the Oil Tank Cap. Clean paint out of the pivot sleeve in rear brake plate. Clean up and polish the front brake plate. Clean up the rear brake shoes. Clean up and re-line the front brake shoes. Test the white primer paint to see if it is long term OK in hot oil. --------------------------------------------------------------------------- Rear Wheel Bearing Inner race and rollers I.D. 0.620" Thickness 0.890" Timken 1130N1 Outer race O.D. 1.750" Thickness 0.565" Timken 1178X A B C D F G Drag Size anfly BSA Hoffman, Bore x OD Part Part Timken or Type Thickness No. No. M=Matchles Torrington ---- --------- ------ ------- ---------- -------------- 5/8 x Taper 1 3/4 x 24-6860 24-6860 M-014868 K1178X/K1130NI Roller 13/16 --------------------------------------------------------------------------- Fork Tubes for old bikes: Franks' Maintenance and Engineering 945 Pitner Avenue Evanston, Illinois 60202 --------------------------------------------------------------------------- October 2001 Subject: BSA M21 Parts Order Hello, I would like to order the items listed below. Please charge this order to my VISA Card which is number: I believe that I'm customer No. 122892 with your company. The shipping address is: Daniel Edmunds 231 Durand St East Lansing, MI 48823 USA Thank you for your help with this order. If there are any questions please contact me via email using the address: Edmunds@pa.msu.edu Est. Cost Qty Part Number Description Each --- ----------- ---------------------------------- ------- 2 24-6860 Rear wheel bearings M21 Rigid 23.76 1 35-6432 Rear Brake Shoe Lining (pair) 10.90 1 65-3506 Gear Box Sprocket 19T 20.23 1 65-4960 Handle Bars 14.00 2 65-5904 Front Brake Shoe Springs 1.73 1 65-8502/3 Handle Bar Grips (pair) 3.20 2 66-4903 Chaincase Distance Sleeve 3.00 1 66-8358 Oil Filter Cap (top) Complete not in catalog 1 66-6979 Rear Carrier for M20 Rigid Frame 25.92 1 66-7032 Rear Brake Pedal Return Spring 4.68 1 SSU700P Headlight Shell Lens-Reflector Rim 58.30 Switch Panel Switch Amp Meter Pilot --------------------------------------------------------------------------- Brake Shoes The shoes from the front wheel that came with the M21 say part number 67-5558 on the aluminum part. There is also the mark "MCL" in a square box on the aluminum part. The replacement linings for the front shoes are: I'm 90% sure that the front wheel is what is called and 8" brake. The shoes from the rear wheel that came with the M21 say part number 35-9235 on the aluminum part. They look more dye cast than sand cast. ---------------------------------------------------------------------------- Rear Wheel Bearings The new rear wheel bearings obtained in the Oct 2001 order to dragonfly are reworked modern beaarings. They are stamped "LYC 7204 E". The OD of the outer race has been ground down to fit the ID of the Hub i.e. 1.750" A small adaptor has been pressed into the inner race to adapt the ID of the inner race of this new beaaring ( 2.00 cm ) to the 0.625" axil shaft diameter. The adaptor looks like +--+ | | | +---------+ | | Flang |............| OD | | OD 2.00 cm 1.125" | | ID 0.625" |............| | | | +---------+ | | +--+ total length 0.690" flang length 0.200" ---------------------------------------------------------------------------- Spokes Wheel Re-Assembly The M21 wheels are going back together with original spokes except for the rear wheel chain side which has new spokes. The front wheel is original spokes and nipples. The rear wheel is original right side spokes but new chain side spokes and all new nipples. ---------------------------------------------------------------------------- Summer 2002 Machine Work * Fork Tubes Cut Taper Thread * Make a Tool to Install the Fork Tubes into the Yokes * Make a tool to install the seal holds onto the lower fork legs * DeChrome and Straighten Fork Lower Leg Seal Holders -> prime & paint * Put Brake Linings onto Front Brake Shoes Put Cylinder Nuts into MagDyno Straps -> paint Straighten the Front Frame Cover -> paint * Make sleeve for the upper seat tube stays stud Prime and Paint p Foot Rest to Primary Chain Case Distance Sleeves 2x Fork Lower Leg Seal Holders 4x p Brake Springs 4x p Brake Shoes 4x p Front Brake Plate inside p Front Brake Plate Stay Stud and Nut p Front Axle p Rear Axle Washers ?x Tool Box * Exposed part of the Fork Tubes Paint * Seat Front Frame Cover * Brake Pedal Spring Plate * Engine Plates 4x * Bracket Plate to Oil Tank and Battery * Battery Straps 2x * Engine to MagDyno Straps 2x * Mag to Dyno Straps 2x * Front Fender Stays 4x * Wheel Rims 2x * Lower Fork Legs 2x * Rear Brake Plate * Front Brake Plate Stay * Engine steady stay * Brake light switch plate Other Major Work Items Rear Fender full rework Center Mount on Front Fender Seal the inside of the Oil Tank Gas Tank: outside, inside, badge dents Make a Stearing Damper Make Seat Spring Support and Studs (and Fender mount point ?) * Tire Security Bolts clean up, remove rust, paint Top yoke key lock bracket * True the wheels 2x Mount tiers ---------------------------------------------------------------------------- Dave Smith Classic Motorcycles 815 254 3998 Plainfield Illinois http://www.smithclassics.com http://www.btinternet.com/~hawkshaw.motorcycles/alternatorpics.html oldbikebarn http://www.f2motorcycles.ltd.uk/restoration.html \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ Piston the original piston removed from the M21 On the top it has stamped into it: 66-1039, V 160 wit a circle around it, 7, D/T with a circle around it, H, BSA and piled arms Cast into the inside it has: 66-854, BSA It measures: 81.8 mm at the bottom of the skirt in direction of the pin 81.6 mm at the top of the skirt perpendicular to the pin standard bore is 82mm Measure the cylinder barrel: Top of the cylinder - parallel to gudgeon pin 3.2305" 3.230" - perpendicular to gudgeon pin 3.2295" 3.229" Bottom of the cylinder - parallel to gudgeon pin 3.230"" 3.229" - perpendicular to gudgeon pin 3.229"" 3.2285" This is an average of 3.22944" = 82.028 mm another indication of standard 82 mm bore. The new replacement "20 mil oversize" piston measures 3.230" or 3.231" diameter and it appears to be about circular in cross section. \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ Magneto Disassembly Section Rev. Winter-2006 At the points end the side of the bearing inner race with no lettering on it is up against the large diameter brass rotor piece. At the front end of the magneto armature the side of the bearing inner race that says, "UT6 A15" faces the pickup piece. Between the race and the pickup piece there is: a thin washer, a thick washer, the steel oil slinger dished piece, and then a piece of cloth over the front surface of the pickup rotor piece. That piece of cloth had been soaked in varnish and the pickup rotor piece had been varnished to the armature sharft to make it a snug fit on the armature shaft. Coil wire end with the hook is the GND wire. The straight coil wire is the points wire. The capacitor is 0.3 uFd. Looking at the points end of the armature, with the armature rotated so that the HV wire is on top, then the GND wire is on top and the points wire is on the bottom. The "rotatable cam" is 1.42" OD with a bore of 0.6". The thick part of the rotatable cam is 0.155 thick. Overall the armature shaft is about 6.4" long. It is about 2.16" diameter at the rear GND ring part. The shaft is about 0.590" dia where both the front and rear bearing inner races go on. The shaft is about 0.685" dia where the pickup rotor piece goes on. \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ M21 Engine Crankshaft Bearings Section Rev. 7-FEB-2006 Drive Side Ball Bearing (outer bearing) 65-2045 Drive Side Roller Bearing (inner bearing) 24-724 Gear Side Roller Bearing (inner bearing) 24-722 Gear Side Ball Bearing (outer bearing) 27-261 A B C D E G H I J Drag Hoffman Size anfly BSA BSA Timken Bore x OD Part Part Triumph or Tor- Type Thickness No. No. No. rington R & M SKF FAG ---- --------- ------ ------- ------- ------- ----- ----- ----- 25 x Ball 52 x T34 65-2045 66-1625 125 LJ25 6205 6205 15 Roller 25 x Single 62 x 24-724 65-2044 70-9974 R325L MRJA25 NF305 NF305 Lip 17 Roller 7/8 x Single 2 1/4 x 24-722A 24-722A RM9L MRJA7/8 CFM7 RM9L4 Lip 11/16 7/8 x Ball 2 1/4 x 27-261 27-261 MS9 MJ7/8 RMS7 MS9 11/16 A B C D E F G H I J Drag Size anfly BSA BSA A=Ariel Hoffman, Bore x OD Part Part Triumph L=Lucas Timken or Type Thickness No. No. No. M=Matchles Torrington R & M SKF FAG ---- --------- ------ ------- ------- ---------- ---------- ----- ----- ----- \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ Gears and RPMs -------------- 26-FEB-2006 Timing Side Gears Crankshaft Pinion 18 T Camshaft Pinions 36 T Idler Gear 60 T Magneto Pinion 36 T Magneto Fabric Gear 58 T Dynamo Pinion 22 T This implies that the Dynamo turns 1.318 times faster than the engine. Drive Side Gears Engine Output "Cush Drive Gear" 20 T Transmission Input "Chainwheel Gear" 43 T Transmission Output "Gearbox Sprocket" 19 T Rear Wheel Gear 42 T This implies that the transmission output shaft turns 2.2105 times faster than the rear wheel. And it implies that the engine turns 2.15 times faster than the transmission input shaft. Thus in 4th gear, i.e. 1:1 through the transmission, the engine turns 4.7526 times faster than the rear wheel. Rear Wheel Circumference The 3.25 x 19 rear wheel appears to have a circumference of about 82.8" when new. This implies 765.2 turns of the rear wheel per mile. Thus at a speed of 1 mph the rear wheel turns at 12.75 rpm. Put it all together In 4th gear at a speed of 1 mph the engine turns at 60.6 rpm. In 4th gear at a speed of 1 mph the dynamo turns at 79.9 rpm. In 4th gear at a speed of: 25 mph turns the engine at 1515 rpm and the dynamo at 1998 rpm. 35 mph turns the engine at 2121 rpm and the dynamo at 2797 rpm. 45 mph turns the engine at 2727 rpm and the dynamo at 3596 rpm. 55 mph turns the engine at 3333 rpm and the dynamo at 4395 rpm. \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ M21 Crankshaft Rebuild 18-MAR-2006 Dissasemble the crankshaft was straight forward. The connecting rod big end bearing looks OK. The main reason for rebuilding the crankshaft was that the drive side main bearing had clearly been turning on the drive side shaft and had warn it to about 1/2 mil underside. Cut the rivits and remove the drive side shaft from the drive side flywheel. There is a Green paint mark on one side of the connecting rod, but I lost track of which side of the connecting rod was facing the timing/drive side of the engine. The crankshaft to connecting rod big end bearing looks - not great - but it looks servicable. On the inside of the connecting rod big end shell you can clearly see where the rollers have run, it looks like a mat finish, but there are no pits. The rollers look clean. Where the rollers have run on the pin you can see a mat finish and there is one small pit. With the big end assembled you can not feel any motion in the bearing. 19-MAY-2006 Order to Dragandfly to get a replacement piston ... and new rollers for the connecting rod big end. 11-June-2006 Finish cleaning and paint the flywheels. Can the Output drive side shaft be connected to its flywheel with Alan flat head screws instead of the rivets ? There appears to be plenty of metal in the flywheel to make the holes slightly larger and the flange on the drive side shaft is thick enough. What size alan bolts ? The rivets are 0.183" diameter and are a loose fit in the flywheel holes. The outside of a 10-24 screw that measures 0.188" is a tight fit in the flywheel holes. So what size screw needs a tap hole that is just a little larger than 0.188" ? Screw Drill Probable Size Size Hole Size ------ ----- --------- 12-24 0.177 0.1805 12-28 0.180 0.1835 1/4-20 0.201 0.2048 1/4-28 0.213 0.2168 So all of the #12 screws are too small. 1/4-20 The flange on the drive side shaft is about 0.245" thick. The thickness of the part of the flywheel where the bolt or rivet goes through is about 0.605". 0.245" + 0.605" = 0.850" 2-July-2006 measure many aspects of drive side parts of the crankshaft. - On the cam side of the flywheel the rivets stick up out of the shaft flange, i.e. stick in toward the connecting rod, by 45 mil max and 40 mil typical. - A M5 nut is about 0.314" i.e. 8mm across flats A M6 nut is about 0.387" i.e. 10mm across flats - The build out on the hub of the drive side flywheel is 0.203" or 0.205" tall. - The build out on the hub of the drive side flywheel has a 0.245" to 0.290" wide lip. This build out is not centered on the shaft. - The build out on the hub of the drive side flywheel is about 1.505" dia. - The drive side shaft is 0.984" diameter 25mm diameter. - The OD of a 8mm thin wall socket that fits a M5 nut is 0.465". The OD of a 10mm thin wall socket that fits a M6 nut is 0.545 - Cutting into the drive side flywheel hub build out enough to fit a M6 nut does not look too bad. - Cutting into the drive side flywheel hub build out enough to fit a 10mm thin wall socket is too much of a cut. Veto this. - The hub of the drive side flywheel where the bolts must go through is about 0.592" thick. - The flywheel bolts/rivets are in a circle that is about 1.75" or 1.80" diameter. - The flange on the drive side shaft is 0.245" thick. - The head of an M6 Alan bolt is about 0.398" diameter 10.1 mm dia. - The counter sink on the top side of the drive side shaft flange is so big that it is too big to tap this hole for an M6 thread, i.e. you can not thread an M6 bolt into the shaft flange. - The drive shaft has a 3.0" push in length, i.e. the stroke of the press would need to be >3" to press in the shaft in one push. - The stroke of the press that we have is 2" maximum. - The M6 flat head alan bolts that I current have are about 0.231" shank diameter and about 0.230" thread diameter. Their shank lasts for about 0.525" from the top of their head and for about 0.365 from the bottom of their head. - The ID of the bearing in the big end of the connecting rod is about 1.77" ID. - The connecting rod little end bearing is about 0.75" ID and 0.945" OD. Yet more measurements and analysis about trying to cut the build out to fit a 10mm socket. - The flywheel hub build out is 0.205" tall. - The flywheel hub build out is 0.245" thick at its thinest spot. - An M6 hex nut is 0.195" tall, i.e. it will fit in under the height of the build out with 10 mils to spare. - An M6 hex nut is 10mm across flats and about 0.440" across points. - The contact foot print of an M6 hex nut is a circle about 0.390" or 0.400" in diameter. - The O.D. of the 10mm thin wall socket is 0.545". - Mill end mill tools: 7/16" = 0.4375" 1/2" 9/16" = 0.5625" - 15/64 reem is 0.234" #1 drill bit is 0.228" - The existing rivet holes in the flywheel are about 0.191" diameter. - At the thinest spot on the build out, the distance from the center of the rivet hole to the vertical edge of the build out is 0.162". Thus is you want a 0.550" diameter cut into the build out centered on the rivet hole, this will but into the build out 0.113" and leave the build out only 0.132" thick at it thinest spot. This will then fit a 10mm socket. Thus is you want a 0.450" diameter cut into the build out centered on the rivet hole, this will but into the build out 0.063" and leave the build out only 0.182" thick at it thinest spot. This will then fit a M6 hex nut. As above this looks very thin if you cut it for the socket. Can you use normal allen bolts and after installed grind down their heads ? - This idea is to counter bore the drive shaft flange to a depth of 50 mils or so, just enough to fit the allen bolt head, and then after installation grind off the allen bolt head leaving only 45 mils of so proud of the drive shaft flange. This would leave the allen bolt head about 95 mils tall. - The hub of the drive side flywheel where the rivets (blots) must go through is about 0.592" thick. Find an allen bolt that will use about 0.300" of this for its shank and thus leace about 0.290" of the drive side flywheel hub to be tapped for the allen bolt threads. Current possible plan: - Test and measure the "pot life" of the Loctite both for the press in shaft and on threads. _ Get M6 flat head alan bolts with longer shanks ? - Mill the build out on the hub of the drive side flywheel so that you can fit in M6 nuts on bolts coming through the 5 center holes and fit in M5 nuts on bolts coming through the 2 outer holles. - Cut 5 of the M6 flat head bolts to the correct length. Cut 2 of the M5 flat head bolts to the correct length. - Get washers for use under the nuts, i.e. between the nuts and the cast iron flywheel hub. Will nut plus washer be too tall ? - With the Loctite press the drive side shaft into its flywheel in two strokes of the press. Use Loctite on both the shaft and under the flange. How to setup and control the index of the shaft in the flywheel ? - After pressing in, verify that the shaft is indexed into the flywheel OK and then put it back in the press for 3 days pressing on the whole flange at N tons. - For the 5 central holes in the flange, drill ream the holes through the shaft flange and flywheel hub to about 0.230". Then counter sink these 5 holes in the shaft flange to fit the 90 degree heads of the M6 flat head bolts. - For the 2 outter holes in the flange, verify that you can push in the M5 bolts - ream if necessary. Then counter sink these 2 holes in the shaft flange to fit the heads of the M5 flat head bolts. - Install the bolts using Locktite on both the threads and on the bolt shank and under the bolt head. - After full tightening of all 7 bolts then grind the heads of the 2 outer bolts if necessary to maintain the clearance around the center pin. The crank pin had a screw in plug that had a narrow straight blade screwdriver slot to install and remove it (like lots of English stuff seems to like to use). This plug was screwed in too tight to remove it with a screwdriver. With the crankpin in the mill I first cut through the plug with a 3/16 tool and then a 1/4" tool. This was in the center of the plug. Next moved a few mills at a time toward one edge, until I detected the threads, and then back to center and toward another edge. The shell of the old plug wound around the mill tool and came out. The threads in the plug were still good. I assume that these threads were 5/16" x 26 tpi but I cleaned them up with a 5/16" 24 tpi tap and they look good. There are about 6 full turns of clean threads. The threads end right about where the tappered part of the pin starts. This is 0.3" or so away from the oil feed hole, i.e. well clear of the oil feed hole. Now a standard 1/4" long 5/16" 24 tpi allen set screw will work just fine for a plug. \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ I got the work back from E&V Engineering on 15-Aug-09. I finally had time to start looking at it closely on 24-Aug-09. - The new Exhaust Guide measures 0.954" down from the deck. The target for the Exhaust Guide is 15/16" = 0.9375", i.e. 16 mils low. - The new Intake Guide measures 1.063" down from the deck. The target for the Intake Guide is 1 1/8" = 1.125", i.e. 62 mils high. - The bore in the barrel now measures about 3.252" or 3.253". The original bore was 82mm = 3.2283". 20 mil over size is 3.2283 + 0.020 = 3.2483 Clearance on the piston skirt should be 4 to 6 mils. Ring gap should be 8 to 10 mils. \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ American/United National Threads TPI TPI Root Dia. Size Diameter Coarse Fine Coarse ---- -------- ------ ---- --------- #0 0.0600 - 80 0.0447 #1 0.0730 64 72 0.0560 #2 0.0860 56 64 0.0668 #3 0.0990 48 56 0.0771 #4 0.1120 40 48 0.0813 #5 0.1250 40 44 0.0971 #6 0.1380 32 40 0.1073 #8 0.1640 32 36 0.1299 #10 0.1900 24 32 0.1570 #12 0.2160 24 28 0.1722 1/4" 0.2500 20 28 0.1850 5/16" 0.3125 18 24 0.2400 3/8" 0.3750 16 24 0.2940 7/16" 0.4375 14 20 0.3440 1/2" 0.5000 13 20 0.4000 9/16" 0.5625 12 18 0.4540 5/8" 0.6250 11 18 0.5070 3/4" 0.7500 10 16 0.6200 7/8" 0.8750 9 14 0.7310 1" 1.0000 8 12 0.8370 M2.5 0.098" M2.6 0.102 M3 0.118 M4 0.157 M5 metric is about 0.196" diameter M6 metric is about 0.236" diameter \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ Work List 16-July-2006 Crankshaft rebuild. - drive side shaft install in flywheel - center pin clean up and new end plug Connecting Rod fully clean up and examine its big-end outer race then install a new small-end bush. pr Un-bend the brake pedal and then re-paint as required. pr* Clean, Prime and Paint the stearing damper belville washer. k Clean, Prime and Paint the "shake proof" body washers. pr Un-bend the front engine sheet metal cover and then re-paint as required. k Find and prep (drill to size, prime, and paint) some washers for the foot rest threaded rod. pr Clean, Prime and Paint the machine screws and washers to hold the oil tank bracket to the frame and hold the oil tank to the oil tank bracket. k Clean, Prime and Paint the replacement bolt that goes through the engine plates and the replacement bolt that holds the front of the transmission to the engine plates. k Clean, Prime and Paint the brake light switch pr Clean, de-rust, and then prime the inside of the oil tank. Cut the rubber stearing stops and attach to the stearing stop bracket and paint. k Final seat assembly and painting. Final assembly and painting of the crank case breather. Final tightening of rear wheel nipples and then re-paint as required. \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/ Magneto Re-Assembly Oct-09 I will flip the direction of the inner races when I put them back on. That is: the front (drive end) race will go on with the side that says "UT6 A15" facing out toward the engine and at the points end the inner race will go on with its no lettering side facing out toward the points cover. The ball assembly from the back bearing looks in better condition than the one from the front - so I will swap them so that the best one is in front where the most load is. Originally there were 3 things that spaced out the front inner bearing race: the oil slinger 15 mil thick, the thin spacer washer 10 mil thick, and the thick washer 50 mil thick. As the first try I will leave out the thin washer and the oil slinger - this should compensate for the slightly longer "armature". \/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/