Sean's Bonny Motor Rebuild - VIII - Primary & Timing Case Assembly

01/30/05, 2/22/05

Assembled primary drive, charging system, oiling system, and timing case. Notes below.

notes:

Installed inner primary sprocket cover with new gasket and oil seal. Anaerobic sealer used. Threads in case inspected and good.
Clutch and friction plate grooves in clutch hub and shell inspected. Minimal wear found.
Motor sprocket inspected and found to be in excellent shape
Installed new sprocket shaft oil seal.
Sprocket oiler drip tube installed.
Clutch roller bearings, hub, and shell races inspected and found to be in very good shape with a close fit.
Clutch plates and friction plates inspected and found to be flat and in very good shape.
Primary chain inspected and found to be in excellent shape. It is a master-link type chain.
Clutch hub, bearing shell installed with new thrust washer.
Motor sprocket and primary chain installed.
Primary chain tensioner was grooved (as they all are) but in useable shape. Retaining washer for the tensioner rod was about to give way. The flared end of the rod was also damaged. Welded new shoulder onto rod and installed new retaining washer.
Installed clutch hub nut with 242 threadlocker and torqued to approx. 60 ft/lbs.
Installed rotor, new lock tab washer, and nut. Torqued to approx. 60 ft/lbs.
Installed stator stand-off studs with a drop of 262 threadlocker. Threads in case bosses were perfect.
Installed stator, new stator lead case seal, fed leads through case. Torqued stator nuts to 15 ft/lbs using 242 threadlocker. Confirm min. .007 clearance between stator and rotor at all points.
Installed clutch & friction plates, release disk, and new clutch springs. Adjusted clutch stud nuts until release disk threw-out square. Use wicking-type threadlocker on adjuster nuts.
Confirmed that oil passages in case and timing cover were clear.
Installed oil feed pipes with new gasket and anaerobic sealer. Used 242 threadlocker on retainer nut.
Confirmed that oil pump gasket holes aligned with those in pump boss. Opened lower feed hole slightly.
Oil pump previously inspected and found to be in very good shape.
Primed oil pump and passages with motor oil, installed pump. Used 242 threadlocker on retaining nuts and torqued to 55 in/lbs.
Installed idler gear in timing case and ensured proper timing of cam and pinion gears to T120 specs. Idler gear bushing found to be close fit on shaft.
Repaired damaged oil plug in timing case by tapping to 1/8NPT and installing socket-head pipe plug. Confirmed unobstructed oil passage from pinion oiler gallery to exit passage in lower right of cover.
Installed new pinion shaft oil with existing retainer clip. Used anaerobic sealer at perimeter. Seal is snug fit in boss as not to allow oil to seep around it.
Installed new cam oil seal in timing cover. Used sealer at perimeter.
Installed new timing cover gasket with anaerobic sealer. Coated all gears with assembly lube. Installed cover with new fasteners and 242 threadlocker. All thread bosses in case in good shape. Torqued fasteners to 110 in/lbs.
Primed oil feed circuit, installed oil pressure relief valve in case, capped off line. Pressure relief valve inspected and found to be in good shape. Installed in case with sealer.