Gearbox transmission clutch, belt drive

Speedo drive was removed and plated off.

Ugly sludge in the gearbox. Needs a good flush out

Oil slinger is loose. The end of the shaft has had a beating. The snapring groove is partially peened over. It needs better spacing so the slinger gets held true. Slinger has been brazed in the past, now broken away.

Worn through hardening..

Made new clutch puller from x-profiler cutter's scrap steel. 3/4" bolt.

Cut down inner primary. Bearing is very loose in housing. Chain been rubbing.

Belt tensioner roller, fits ratchet adjustment.

Very big o-ring chain with 25T sprocket

Speedo drive 11T, so it runs a 2:1 speedo, now removed.

I cleaned the paint from around engine bolts holes otherwise paint can migrate out and loosen bolts.

11T speedo drive, redundant in favor of front wheel cable drive.

 ...and it turned out to be cracked...

Chain rubbing about 1mm deep.

Drive sprocket spline has a piece chipped out exposing the shaft seal beneath. See pic at 12o'clock

Possible addition to the belt drive is this alternator cover..

Gearbox number giving the year as 1975

Clean up the gearbox. Paint came off easily.

Drilled and inserted 5mm magnet in gearbox drainplug.

Crank nut cleaned up and zinc plated. Washer made from real tough steel. Was difficult to machine.

Mock assembled. 

Clutch plate linings narrowed to 20mm. This allows them to free better. I may go narrower and segment them but will wait to see if they perform OK. Because they are sintered, main thing is they don't behave grabby. If they are grabby, they will be replaced.

Update: they were chattery so were replaced with grey semi-sintered linings. These were narrowed to 18mm.

Never=sieze on studs and basket segments. Taking care not to overdo because it will end up splattered on plates. A light smear only. Important to put it on studs were spring rub. It makes a difference you can feel.

Belt drive guards to stop stones etc.

Outer guard in the making. 3mm aluminum.

Inner guard bolted. The rear bolt hole is slotted to allow for belt adjustment. The bolt heads by alternator turned out to be too long and rubbed belt.

This is how the inner primary guard is mounted off the gearbox. It helps remove stress from having the aluminum expand and tightening the belt.

Recycled belt buckle badge.

27 Oct 2023 Made a +0.005" oversize pin for clutch lever to address wear. Stainless 304

Mousetrap rod end made from 10-40 steel. Pin made from a 1/2" 8.8 bolt.

Rod end ball joint where it fits clutch release lever

Ali pressure plate was out-of-true from new. I machined 0.014" to clean it up.