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Light Cruiser rebuild

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Light Cruiser rebuild

Post  Cruiser79 on Mon Mar 27, 2017 8:50 pm

Hi guys,
         After being stalled for ten years with the bike in boxes I've finally got around to making a start on the Light Cruiser again. Hoping to use this thread to ask questions as I go. Many thanks for any words of wisdom or help!

I've split the 17T box and crank cases to go over the work a nineteen year old me did all those years ago, crank is spot on so will be joining the cases back together tomorrow. The gear box is another story. Pics as found below and how it is today after some work. I've replaced both g/b main shaft bearings, cleaned all the parts and checked for wear and tear. The phosphor bronze bush for the foot change shaft is toast, huge amount of wobble when the shaft is fitted in the bush. Is this available anywhere to buy new? I know its an easy enough part to make but alas I haven't got a lathe so will have to pay an engineering company to make a new bush otherwise. (Indicated in pics and part no. 110 in the spares diagram)

Next question is seals, I have NOS gear box output and crank seals but am uneasy about using them due to age and hardness, also the g/b seal looks to be a slightly loose fit in the housing so will need to source a modern equivalent with rubber coated outer. Are these sizes still available from any specialists if the local seal/bearing shop hasn't got them?

I'm building the engine with a view to it not marking it's territory everywhere it goes. The gasket for the gear box end cover is waffer thin, almost too thin to my eye especially as theres pitted corrosion on the sealing faces. Would it be safe to put two old stock gaskets in together with Wellseal either side or even just make a slightly thicker single gasket up? Would the slightly thicker gasket upset clearances in the box?

Finally if anyone has one of the near mythical 17T +060 pistons with rings which they would be happy to part with I would do cash or trade nos/used engine spares. I have bits for 17T/25T to trade





The horror

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Rebuild

Post  kerabo on Tue Mar 28, 2017 6:44 am

It looks like your doing a grand job there

That bush is a strange thing to wear as it has little use. If you buy an old casing from eBay and use its bush.

I find the best place for gaskets is in the bin. I use Halfords silver jointing compound.
Unless the gasket is a spacer. Of course you must not use it too thick.
Another thing I done was to flatt all surfaces on some production paper.

Regards Ken
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Re: Light Cruiser rebuild

Post  Cruiser79 on Tue Mar 28, 2017 5:13 pm

Thanks Ken, Maybe that particular bush was just a loose fit from the factory? like you say it isn't exactly a busy part in the grand scheme of the box. It just has what to me seems like very excessive play. I'll crack open another box and see if its the same, if so will just run with it.

I went to a seal supplier today with the crank and gear box seals and they were stumped by them, they had never come across the sizes and they don't have anything which fits the bill. Am I stuck using old stock seals or can they be found new elsewhere?
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Rebuild

Post  kerabo on Tue Mar 28, 2017 8:18 pm

I am sure Villiers Services have Crankshaft seals for AMC.

has the other seals got numbers on them.

Regards Ken
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Re: Light Cruiser rebuild

Post  Cruiser79 on Wed Mar 29, 2017 10:05 pm

Thanks Ken, I'll fire an email over to villiers services and see if they can help. Theres numbers and letters on the old stock and used seals but haven't been able to turn anything up with them
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Re: Light Cruiser rebuild

Post  kerabo on Thu Mar 30, 2017 4:20 am

Cruiser79 wrote:Thanks Ken, I'll fire an email over to villiers services and see if they can help. Theres numbers and letters on the old stock and used seals but haven't been able to turn anything up with them

Phone them
Whenever I questioned where is my order they say phone it's much easier .
Ken
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Re: Light Cruiser rebuild

Post  Cruiser79 on Fri Mar 31, 2017 4:25 pm

I seem to be missing a boomerang shaped bracket for the side panels which mounts to the rear two cylinder base studs? Would anyone have one or even be able to send me a paper template of their own so I could make one?


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Bracket for panels

Post  piston 197 on Fri Mar 31, 2017 5:36 pm

Just sent my last one to Jim Johnstone, if he sees this he may be ably to help ?

John H
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Light Cruiser 79 Side Panel Bracket

Post  jimjohnstone on Tue Apr 04, 2017 10:28 am

Hi Cruiser 79,

If you give me your email address, I will send the pictures of the bracket I have and I will make you a card template of the item. If you wish to discuss, please call me on 07952 741029.

Best regards
Jim Johnstone

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Coil bracket

Post  piston 197 on Tue Apr 04, 2017 10:48 am

Someone asked me for a coil bracket as shown in picture above for the light Cruiser, have found it now, but have lost the contact number for who it was who asked me ? If it was you, or if someone else needs one ( as it was a while ago and the original person may have now found one ?)send me a p.m.
JH
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Re: Light Cruiser rebuild

Post  Cruiser79 on Wed Apr 05, 2017 5:17 pm

PM sent Jim. Many thanks for the offer.

JH the coil bracket wouldn't have been myself but hopefully who ever it was spots your message.

I started tackling the clutch last night. There are enough good plates to make one, maybe two usable clutches. All the rest are too far gone.
The clutch drum when spun sounded very grumbly which I think is down to general crud and rust between the back plate and friction inserts as pictured. The bearings themselves seem fine so will clean everything up and reassemble. Does anyone know what sort of thickness I should have on the friction material which the back plate works against? Theres quite a bit of crud on them so still need to flat them back to good material, currently as pictured they're in the 1.75-2mm range. Is that within spec? I do have a bag of clutch inserts which seem a bit thick for this job at ~ 5mm / .200" thick. Will I get away with the originals or if not would my replacements suit?



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Re: Light Cruiser rebuild

Post  Cruiser79 on Wed Apr 19, 2017 10:11 pm

Evening all,
              I've refitted the gearbox end cover temporarily and have a horrible ratcheting noise when the box is turned over, it does it in all gears including neutral. All gears and neutral select and appear to work as they should at first glance. The kick start shaft fires about a bit like a machine gun so I'm guessing its an assembly issue with the kick start ratchet maybe? The kick start shaft turns the box over and returns as it should. In my head I'm sure I put it all back together correctly, but obviously not! Would anyone have any ideas what I've done wrong? Video attached




Other question is about the gear change ratchet, it can fit on the splines in a few different positions. Would anyone be able to tell me where say the central projection should sit on the face of a clock in a particular gear?


Last edited by Cruiser79 on Tue Apr 25, 2017 3:12 pm; edited 1 time in total
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Re: Light Cruiser rebuild

Post  Jack Clegg on Thu Apr 20, 2017 10:35 am

Sounds exactly like the kickstart pawl is not parking/closing in the return position.
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Re: Light Cruiser rebuild

Post  Cruiser79 on Fri Apr 21, 2017 9:11 pm

Jack Clegg wrote:Sounds exactly like the kickstart pawl is not parking/closing in the return position.

Many thanks for your reply, I think you're right. When I assembled the box I had all the internals (kick start shaft included) assembled into the lay shaft. Then I installed the bare end cover and once wound down flush I fitted the main shaft nut (part 45), clutch operating body (part 50) and finally the kick start return spring.
Should the kick start shaft (part 53) with spring be assembled into the end plate before assembly and the kick start lever temporarily fitted and held down under tension as the end cover/ks shaft are fitted and meshed with the ks ratchet (part 54)? This might explain why its firing like a machine gun when turned over?
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Re: Light Cruiser rebuild

Post  dalgrae on Sat Apr 22, 2017 7:54 am

For the oil seals try Bearing Boys website ,I just bought the primary case seal for my 15t engine

Regards. Colin

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AMC rebuild

Post  kerabo on Mon Apr 24, 2017 7:18 am

If you pm me your email address I will send you some rebuild information.

Are you a member?

Regards Ken
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Re: Light Cruiser rebuild

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