T140 Case Welded After Broken Primary Chain

[RobinV]

Hello all. I got the T140 1978 1/2 back from the welder. I mocked everything up and it looks like a pretty close fit rotor and stator.. May have to make minor adjustments. NOS clutch basket and NOS main drive gear, which fits snug w/o play on the crank shaft splines.
So now, I have a question of you with experience, which I have not. I can fit all pieces, but when I snug the clutch hub to the shaft, it binds and locks to the basket. Does not spin free. I have looked at manuals, and videos, but cannot see what I am doing wrong. Looks like the tapered shaft stops the bub from going too far back. But again, once lightly tightened my hub and basket become one moving assembly. Hmm. What am I missing here? Appreciate any tips. Best regards, Robin.

 

[RobinV]

Just watched another video. The only thrust washer is the one with two tabs behind the basket. Is there supposed to be one on the other side? This bike did not have one. Thanks.

 

[RobinV]

OK. Well I have explored a little further. I assembled my clutch hub using a bolt to hold it together. Torqued to 59 ft lbs. Spins freely. So, I am assuming that my transmission main shaft must have moved. It is not bent. I can sense axial play of maybe 8 thou. But some yahoo was in there at one time and took a file to it.
Perhaps the didn't like the taper, who knows.
So to fix this machine I would most likely need to remove and replace the output shaft and bearings. Or just move on. I am not sure the degree of difficulty this would entail. Robin

 

[RobinV]

I have succeeded in the installation. I used a different hub and a new woodruff key and extremely carefully fit everything. New drive gear, new basket, and all spins nicely. Phew. Now to check stator alignment and adjust if necessary.

 

[atomsplitter]

Glad it's working out for you, good luck with the remainder of your project.

 

[RobinV]

Thankyou. And on a final note, I was having some issues with alignment of the stator. Went out after dinner and found the perfect steel pipe that was strong and fit over the studs, nuts, and down a ways. Judged the amount of bending needed and got lucky. Perfect alignment A perfect 8 thou all the way round.
On the way back from errands, I devised a perfect tool for primary chain adjustment using a 1/4" drive ratchet. OK. I can sleep well tonight. Robin

 

[sikatri]

Excellent!

 

[RobinV]

And, like the cherry on the top of an ice cream sundae, I got to ride it earlier today. Quiet and smooth with the primary and final drive chains renewed.
I dropped both MK2 needles a notch, there are just three. It was very happy running down the highway, a little rich at idle to my ear. I will look at the new NGKs tomorrow for the mixture story. I should stop extolling the bikes' virtues at this point, else I jinx myself. Best, Robin.

 

[RobinV]

Hello all. The motorcycle runs strong with no oil smoking. Compression at 125lbs both cylinders.
Thankyou, Robin.

 

[Rudie]

I have moved your carburation question to a new thread - T140 Running Rich

 

[RobinV]

Thankyou.