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D1 1954 Plunger frame Build
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BSAdave
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February 18, 2016 - 2:57 pm
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20160218_141300.jpg

20160218_141442.jpg

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D1 D3 D5 D7 Suzuki TS 125, Yamaha YDS7 250

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BSAdave
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February 23, 2016 - 10:12 am
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Looks like the job did not happen, I was/am the best qualified and have the most experience to do the job but they give it to some one that on his own admission does not have a clue what to do and lacks the skills to do the job. On my feed back from the interview I answered all the questions and got top marks except for one, and the question was what weaknesses do you have.

Never mind, this is a Bantam site so lets get back to the Bantam.

On Sunday I put the engine back together, fitting a new spring and ball for the gear selector, I test fitted the gears and dry fitted the two crank cases , I fitted the gear lever and tried all the gears they all selected has they should, i then applied the gasket glue and started to screw the two cases back together , then i remembered I had not bent the two tab washers over so i had to split the cases again,once this was done i cleaned the faces applied new gasket sealer and bolted the engine back together, this time it worked then the gear shaft moved back into the engine and I could not select any gears, so I split them again, I am not sure why this happened but i will try replacing the return spring on the shaft. but looking at it i'm not sure how this comes apart. I have also run out of gasket glue and it was a Sunday night, So it was onto the internet and new gasket sealer ordered then I had to go to work.  

D1 D3 D5 D7 Suzuki TS 125, Yamaha YDS7 250

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Derek's D5
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February 23, 2016 - 1:08 pm
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I had that with mine- the gear shaft can move inwards and then doesn't work. Since I have most of two engines to faff around with, I compared two selector shafts and found the position of the claw was slightly different. I used the one where the claw was further from the end, I think. I also didn't replace the spring, even though I have a new one. It looked really tricky and I didn't want to try it, and then find (as you often do) that the new part is inferior to the old one! This was the case with the ball and spring.

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jess steele
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February 23, 2016 - 3:16 pm
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BSAdave said
i will try replacing the return spring on the shaft. but looking at it i'm not sure how this comes apart.  

It's quite easy Dave,the shroud that covers the return spring has a round circlip holding it to the shaft,remove the circlip and the shroud slides off the shaft as does the return spring.............

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cocorico
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February 23, 2016 - 7:05 pm
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If it's any help - this is what my D3s looked like when apart. You can't see the wire circlip removed from the Rt end of the shaft, but the the selector taps off when it's removed. The top spring is the old one - some difference, eh?IMG_1920.resized.JPG

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BSAdave
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February 24, 2016 - 9:36 am
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cocorico said
If it's any help - this is what my D3s looked like when apart. You can't see the wire circlip removed from the Rt end of the shaft, but the the selector taps off when it's removed. The top spring is the old one - some difference, eh?IMG_1920.resized.JPG

Thank you for that, makes it clearer, the circlip is missing on my mine and the shaft was moving inwards, I have purchased a new one from Rex .

the other issue is I have two of these shafts and one is 12mm longer than the other and when looking at the spare one the circlip is also missing , which one is the right one for a D3 engine ?

D1 D3 D5 D7 Suzuki TS 125, Yamaha YDS7 250

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BSAdave
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February 24, 2016 - 10:40 am
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Yesterday while at work I popped into the Pound land shop and purchased this, I know they are metric but I am always running out of nuts and washers and they come in handy for jobs like when i converted the hospital bed .

I have separated them into separate bags so you can see what you get. They must be good, Tommy Walsh has his name on them. !!!!!!!!!

20160224_103125.jpg

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February 24, 2016 - 11:39 am
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Hi Dave .... Tommy Walsh obviously does not own a Bantam..

NO SPRING WASHERS... ????.... If you use them on a Bantam, after ten minutes ticking over they will be on the floor.

But you probably know that, just thought I would mention it, for any new comer's to the world of Bantam's.

Bob.

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Derek's D5
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February 24, 2016 - 12:24 pm
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Dave, I thought the gear shaft was the same in all of the three speed bantams. I see Rex is selling replacement gear shafts on ebay for £22. Have a quick look and see what models it suits.

Maybe you've got a gear change shaft from another bike? Should be easy enough to check, if you put the gear shaft in place and then put the clutch casing on, you should have enough space to get the kickstart on and then the gearchange lever, and still have a bit of gearchange shaft poking out.

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BSAdave
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February 24, 2016 - 3:05 pm
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Hi Bob , well aware of that but will come in handy for other projects but worth reminding people.

Well that was fun, the engine is now joined together, I replaced the spring, I didn't know that there are two cir-clips but thinking about it there should be. 

20160224_110452.jpg20160224_110608.jpg20160224_111923.jpg

The engine joined together at last.

20160224_145120.jpg

20160224_145042.jpgEngine.jpg

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D1 D3 D5 D7 Suzuki TS 125, Yamaha YDS7 250

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BSAdave
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February 24, 2016 - 3:15 pm
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Hi Dookie,

I tried the method you said and the shorter one did not stick out far enough so used the longer one which was handy as the shorter one splines are knackered  .

I wanted to fit the clutch but the clutch mush room push rod is on order, I received an email saying that the supplier has put it on back order , it did not say at the time of ordering that is was not available. I have placed an advert in the wanted section, so if any one has one for sale that would be great. 

Just got to go and find were I put the piston now, it is some where safe. lol

Do you think it would be OK to start it up in the engine stand ?

D1 D3 D5 D7 Suzuki TS 125, Yamaha YDS7 250

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jess steele
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February 24, 2016 - 4:06 pm
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BSAdave said
Yesterday while at work I popped into the Pound land shop

I was in poundland yesterday to Dave but i didn't see you whistle

I didn't grab tommy's nuts but i did get some of his super glue and his imitation araldite, i only originally went into put up some party hats and balloons...........................get-me-coat

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cocorico
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February 24, 2016 - 4:13 pm
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BSAdave said
... Just got to go and find were I put the piston now, it is some where safe. lol

Do you think it would be OK to start it up in the engine stand ?

Not without the piston ...

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BSAdave
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February 24, 2016 - 8:14 pm
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Found the piston and I even managed to find the cir-clips this as now been fitted just waiting for the new clutch parts to arrive. 

D1 D3 D5 D7 Suzuki TS 125, Yamaha YDS7 250

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Derek's D5
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February 24, 2016 - 8:32 pm
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I probably should have changed my gear change spring. I have a new one in my box of spares. Too late now.frown

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February 24, 2016 - 10:00 pm
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BSAdave said
Found the piston and I even managed to find the cir-clips this as now been fitted just waiting for the new clutch parts to arrive. 

If I were you I would have replaced the circlips for new, old circlips refitted have caused many damaged engines when they pop out.

"H"

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BSAdave
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February 25, 2016 - 8:20 am
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Hi H,

They are new ones, it amazed me that I actually knew where i had put them.

If you look at the scan you can see the difference in size between the old ones and new

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D1 D3 D5 D7 Suzuki TS 125, Yamaha YDS7 250

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Mags 1
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February 25, 2016 - 9:49 am
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They almost look like they're designed to fit two different gudgeon pin sizes?

Four now on the road and at least several in bits.

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BSAdave
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February 25, 2016 - 10:22 am
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Mags 1 said
They almost look like they're designed to fit two different gudgeon pin sizes?

That was my first thought, but if you look at the bottom left one you can see it is deformed at the top.

D1 D3 D5 D7 Suzuki TS 125, Yamaha YDS7 250

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BSAdave
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February 25, 2016 - 10:29 am
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You got me worried , lucky I had purchased a spare pair so I laid the old one other the top of the new one which shows the difference. so i think they are the correct ones ?

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