Scooterotica

Tips for an amateur engine builder please

Any tips on fitting the layshaft? Is it possible to fit it fully without a rear hub holder?

The reason I ask is, I have put an engine together a few time in the past, and have tapped it home with a rubber mallet (tapped not bashed) and had no problems, this time though the layshaft seems to be a few mm short of where it needs to be (when fitting the gears, they aren't lining up with the cluster and the end plate cant be fitted)

Is this normal and just a sign that I ought to get myself the correct tools? I've tapped it home as much as I dare and don't want to damage anything.

Cheers
Nick

Nick- you shouldn't need a rear hub "holder" to fit the layshaft.

Make sure the layshaft bearing is correctly "home" and that the holding plate (with the 4 10mm nuts) is fitted, and then tap the layshaft fully home from the end plate side. It should tap into position fairly easily- if it won't then something is amiss.

Chris

Thanks Chris

Any other suggestions as to why the gears aren't lining up correctly and the endplate doesn't seem to sit properly?

The end plate, when sat on the layshaft I assume should fit flush on the cluster side ready to bolt in?

as it is, when I fit the end plate and it is flush on the lay shaft it is about 3 or 4 mm too high to bolt in.

Thanks
Nick

Possibly skimmed the surface of you o ring , have you taken layshaft out to check?

........are you re- buildding with a lay shaft & gearbox you have used before? if not where did you buy them, are they innocenti?

the reason i ask is that i have bought a 'remade' Li 150 box before and it would not line up as it was not correctly machined

...replaced with an original and fitted like a glove, another lesson learned

Hi

Its an original 150 special gearbox - in fact all the internals are original 150 special (1965 Italian) and were fitting OK prior to stripping the engine.

The only thing that has changed is all the engine bearings have been replaced (for good quality italian ones)
and now the lay shaft wont pull in far enough to correctly line up the gearbox and fit the end plate.

I had to give the lay shaft a whack to get it back out - so hopefully haven't knackered the new bearing -

As i said earlier, I have rebuilt engines in the past,but had no problems fitting the lay shaft before.

I'm struggling to see what the problem is, the bearing is definitely seated properly and the lay shaft looks OK

Cheers for the responses guys.

new end plate bearings?

If so are they in far enough? I had one once which was just "proud". The box shimmed up OK, but jammed due to the bearing not being in far enough.

Sorry this is clutching at straws now- can't think what could be wrong

Chris

you did fit the rear bearing from the correct side...?

byron wrote:you did fit the rear bearing from the correct side...?

What do you mean wrong side? Upside down? Is there a wrong way to fit it? Is the inner ring tapered? I guess if there is a slight taper, it could explain it.

I actually had it fitted be a dealer who knows what he is doing, but its worth checking....

Cheers
Nick

so the shoulder of the bearing is in the recess on the brake side of the casing, and the bearing is fairly flush with the inside of the casing ?