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D7 Clutch+ Kickstart and Exhaust
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saab9002
Chandlers ford
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July 30, 2020 - 6:02 pm
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Evening all, 

I've just stripped the clutch plates  primarily to change the kickstart shaft and some of the "corks"

had broken away,(unstuck?) from the friction plate and the others were measuring 2.66mm (0.105")

would I be right in thinking the original thickness was 3.175mm (0.125") ?

The springs free length is 26.6mm (1.047") is that acceptable?

Also there is 1.45mm (0.057") free play of the basket on it's shaft, I haven't

loosened the large nut yet, which is a bit of a concern.

I realise I'm asking for lots of info but it's the first time in 50yrs oldthat I've played with a British bike 

and the Haynes book doesn't seem very inspiring.

regards and thanks again,

Chris

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Number6
Lincolnshire
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July 30, 2020 - 8:26 pm
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Lawks, are these the original cork inserts? On my D3 they were pieces inserted into cut-outs in the plates. Is it like that?

Nonetheless, whichever it is, it's coming apart, scrap and get new modern plates.

Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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saab9002
Chandlers ford
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July 30, 2020 - 11:01 pm
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Hi Number6,

I have already ordered a new set of Surflex friction plates, but I can't find any spec. on the free length 

of the springs and concerned about the play if the basket on it's main shaft.

regards Chris

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Stoo63
GLASGOW
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July 30, 2020 - 11:08 pm
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** Please log in to view **

 '55 D3 Battery; '58 Square Four (project); '59 D1 direct lighting plunger; '59 Tiger Cub; '60 5TA;  '76 FS1-E; '97 Honda Sky SGX50.

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saab9002
Chandlers ford
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July 31, 2020 - 11:24 am
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Hi Stoo63,

Thanks for the tip on the old thread, spring length and clutch plate sizes sorted,

just need to know about the "end float" or play, of the basket now.

thanks again Chris

PS. just made a clutch locking tool, I'll try and put a pic up later.

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saab9002
Chandlers ford
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August 19, 2020 - 5:03 pm
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I ordered a set of Surflex plates + pressure plate also ordered a set of heavy duty springs from Rex, it

all turned up pretty quickly so I stripped out the clutch using a homemade plate and 3 leg puller,also

made a clutch locking tool from an old pair of clutch plates (pics below) found out why the clutch basket

was sliding in and out, the phos. bronze spacer was worn so I made another, replaced the kickstart shaft

and put the clutch back together. All seems ok then turned my attention to the kickstart, it was hitting my

new exhaust and I fancied a folding kicker. Went through all the different folding kickstarts with 3/4" or 19mm

splines and reckoned on a Yamaha RD250 so found one on ebay £17 delivered and set about modifying it. I'm

quite pleased with the result

CIMG1845mod.jpgCIMG1849mod.jpgCIMG1851mod.jpgCIMG1852mod.jpgCIMG1849.JPG

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chickensoup
Bolton, Greater Manchester
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August 22, 2020 - 8:19 pm
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Hi, 

The Rd kickstart looks well, but who made your fancy pants stainless exhaust. Can you post some photo's of the full exhaust system and baffles. Good luck with your clutch repairs.

Kind regards..... Nick

1950 BSA D1 Plunger   242 UYW

1966 BSA D7  LBF 62 D

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saab9002
Chandlers ford
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August 22, 2020 - 11:47 pm
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Will do Nick, give me 24 hrs smile

regards Chris

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saab9002
Chandlers ford
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August 23, 2020 - 1:41 pm
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Hi Nick,

I bought the exhaust from mz-parts-bristol after taking "measurements from a bantam expansion pipe

and compared with these, they were pretty close. Also got some exhaust pipe reducing sleeves from bsa111

I wasn't looking to squeeze every bhp out of my D7 just make it a bit different, ie. pipe, bones ignition,

12volt system and if the carb doesn't want to play, maybe a Mikuni.

I've just built an automatic bike starter/roller which I think is alot better than the ones on ebay, I've used

toothed belts with taper lock bushes not chains and sprockets. I'll put a pic up if you're interested.

regards Chris

CIMG1854mod.jpgCIMG1853mod.jpg

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chickensoup
Bolton, Greater Manchester
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August 23, 2020 - 10:03 pm
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Hi Chris,

the exhaust looks really trick. Being a sheet metal whizz, been thinking of creating my own system, but it looks like you have beat me to it. looks great....

Nick

1950 BSA D1 Plunger   242 UYW

1966 BSA D7  LBF 62 D

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stubaker58
Sunny Felixstowe
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August 24, 2020 - 8:37 am
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Hi,

love the mods, couple of questions ...

what did you have to do to the kickstart to make it fit?

which model MZ was the expansion chamber destined for? And have you run it yet? Is there a noticeable increase in performance?

thanks,

Stu

D7/14 hybrid (4 speed with D7 crank etc.) on the road, D10 Bushman awaiting rebuilding.

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saab9002
Chandlers ford
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August 24, 2020 - 4:38 pm
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stubaker58 said
Hi,

what did you have to do to the kickstart to make it fit?

Stu  

First part was to reduce the length of the clamp part (splines) it was 24mm wide so I reduced it either side by 4.5mm, I'm 

lucky because I run an EDM at work so it was easy, then removed the crank from the swivel pin and jacked up the bottom 

of the face that the crank sits on with a "washer" I machined, 15mm i/d, 25mm o/d and 5.5mm thick then drilled and pinned it

down through the original part either side of the pivot shaft, then dressed it with a file to the same outer shape to allow the

swivel, then drilled another dimple 5.5mm higher for the ball and spring. I've also used countersunk cap heads for the kickstart

and gear change which gives plenty of clearance/non interference of them both. I finished by drilling/ tapping a blind hole M6 hole in the top 

of the pivot and secured them with a washer and bolt.

I haven't had it running with the mods yet, I started this project with just a change to Bones ignition but has grown like topsy

I'm sure you all know what happens with one change which leads to 20 others, and I've been off work for the last 6 months

from bowel surgery then furloughed so it's kept me focussed, also built a push bike for our daughter and as said earlier a

motorcycle starter/roller, sorry hope I haven't bored you all.

Chris

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