Engine sprocket too far in chain alignment problem!!

[Gerry]

Hi all, Took the repaired outer primary cover off this morning as I had managed to get a better one without any welding. Thought I'd check clutch and engine sprocket alignment while I had things apart and found the engine sprocket too far in by about 3/32". I had already had problems previously getting a split pin into the nut as the nut was too far out.
Any way I fitted a spacer between the sprocket carrier and the oil seal ring to align the sprockets and now can't get the nut to reach the threads on the crankshaft! Is there a solution to this problem, has anyone else had it happen to them? Can I do anything to maybe move the clutch basket in closer to the gearbox? I am stumped at the moment. Oh should have mentioned its a four spring clutch. Cheers. Gerry-atric

[A10Boy]

Gerry
A few pictures would be helpful. 

[chaterlea25]

Hi Gerry,
There are loads of topics on this subject already on the forum, do a search!

There are a couple of different crankshaft drive sleeves, the shoulder at the inner end differs
Different clutch adaptors too, the tapers bored to different depths

Make sure to tighten the cushdrive nut to 65ft lbs (more topics on this)

The last A10 I was at I took a load of photos with the intention of writing up an article on primary alignment
Havn't gotten round to it yet

HTH
John

[Gerry]

Hi A10boy & John, Thanks fellas, I did do a half hearted search but the pooch decided it was walk time!! Will try to get some pics up today as its still all in bits. I think I might machine some off the front of the crankshaft sleeve  (why didn't I think of that before) then I may be able to get the nut on far enough to refit the split pin but will still have a job compressing the spring enough to start the nut. Originally I had to machine a smidge off the crankshaft nut so as to be able to get the split pin in which leads me to believe you are smack on John with the "different crankshaft splined sleeves" as this bike came to me in bits, a lot missing too. Had to find a clutch boss off Feebay so maybe that could be the problem but knowing I had to machine the crankshaft nut leads me to think now that the problem lies there. Any idea what the compressed spring length should be? As if I machine off the front of the sleeve its going to allow the nut to run up further and I don't want it coil bound as having already machined the nut I may be going too far. Once everything is correct I think maybe Loctite may be the way to go for the nut. Cheers fellas am now going to do a search for more on the subject. Gerry

[Gerry]

Hi Guys, OK got some pics of the primary sprocket alignment. As can be seen the nut does not reach the shaft (due to my machining it to allow fitment of split pin) may be I should have machined the outer minor diameter instead!!! Hindsight is a wonderful thing or should I say experience....Now going to find an original nut if possible and see what transpires. Gerry

[chaterlea25]

HI Gerry,
My advice would be to remove the inner primary case so as to get a straight edge across the back of the clutch chainwheel and engine sprocket
On the A10 the shoulder on the drive sleeve should be 5/16th in.
Any shims should be added to between the inside of the sleeve shoulder and the crank seal sleeve
Not as you have them between sprocket and shoulder !!!

Engine sprockets seem to come with a variance on the shoulder on the inside
I have NO idea why this is?????

Ignore the splitpin hole !!!!! assemble up the cush sleeve and see that it prootrudes beyond the end of the crank splines, the cushdrive nut MUST be done up TIGHT against the end of the sleeve to 65 ft lbs

The importance of doing this cannot be emphasised enough

The fitted length of the spring is near enough 1 1/8in.

Hope these pics help

John

[chaterlea25]

more pics

John

[Gerry]

Hi John, Many thanks for the great pics and advice, it is appreciated. Actually I have no idea why the pic' of the sleeve, sprocket and spacer in the wrong place was attached!!! Of course if fitted there then the spring would be the only thing holding the rigidity between flywheels against the drive side!! Actually I made a spacer to go exactly where you said it should go, between the mainshaft and the sleeve. The free length of my shock spring is 1.700" not 1.675" so maybe that's another reason why my nut doesn't reach the threads on the shaft besides my having machined it!! Thinking of it now, having machined the nut means the travel of the cam will also be reduced, not good. Looks like a replacement nut, spring and sleeve. Damn!! Will take some more pics and attach. Cheers and thanks again. Gerry

[Gerry]

Hi again Guys, Well all is well!!! I measured the free length of the spring and it comes out at 1.700" so a little over recommended length. To get the nut on I made up a couple of small 'C' clamps out of 1/2" x 1/8" steel and collapsing the spring in the vice added the clamps and slowly released the vice until the clamps held the spring partialy under tension. Then fitted spacer, sleeve, sprocket, outer cam and spring with the clamps attached and screwed on the nut by hand easily for a few turns. Then tightened the nut up and levered the clamps off releasing the spring against the cam and nut. Used a 'C' spanner to tighten the nut with a piece of tube on the end to give me 1 ft. and tightened up with a spring ballance hooked into the tube. Pic's attached. check out the crud that was caused by the misalignment left in the outer case. Luckily the bike has only been run a few times on the stand and not under any load!!! What I don't understand is how I managed to get the alignment so far out originally, what else have I stuffed up? Anyway fitted the outer cover with loctite gasket eliminator between the inner and gasket and grease between the outer and gasket and refilled 225mls of oil. Kicked her over and felt the chain was wet with oil....all good. Now awaiting the return of my exhausts (headers) and silencers (mufflers) which are out for repair and chroming. There's a pair of exhausts on Feebay and I asked what the wall thickness was, answer came back 0.7mm, mine are around 2mm or more!!! Cheers and thanks Guys, much appreciated. Gerry