I get frustration...
Today's build is a case of doing what I can to progress things whilst waiting for bits. The plan is to see what else I'm missing and get a single order to Steve Diffey… First up fit the clutch sprocket and spider. I intend to set the chain alignment properly, as per the advanced engine build section in Sticky's manual, and hence have purchased a complete set of BGM clutch sprocket shims. But there's no point trying to do this until I can tighten down the front sprocket, so I use any old one for now and will measure and change later...
Today's build is a case of doing what I can to progress things whilst waiting for bits. The plan is to see what else I'm missing and get a single order to Steve Diffey… First up fit the clutch sprocket and spider. I intend to set the chain alignment properly, as per the advanced engine build section in Sticky's manual, and hence have purchased a complete set of BGM clutch sprocket shims. But there's no point trying to do this until I can tighten down the front sprocket, so I use any old one for now and will measure and change later...
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I'm fitting a BGM Superstrong clutch, again something that I've had for a while. I'd originally intended to fit it to the Jet, but having replaced the Mugello with the original cast iron barrel this seemed overkill. The barrel was given an old school stage 3 tune by Ian at Taffspeed back in 1992, but nothing stronger than an original clutch with standard springs is required when running with a 22mm Jetex and BGM big-bore exhaust. The BGM clutch is a lovely piece of engineering though, so should be perfect for a TS1. The bronze bush between the sprocket and spider gets a good coating of gearbox oil. Which oil to use seems to be a common question on Facebook, etc. I use Penrite T90, as pictured, although I am now wondering if that's still the correct one to use with the BGM plates? Hmm, better check before filling her up! The chain is a new Scootopia one, which I believe they use for their endurance racers.
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I fit the spider and hand tighten the nut, but can't go any further on this side until my new sprocket spring cap arrives...Time to fit the rear hub. I clean the brake cam and fit a new "fatter" O ring. As far as I can tell the Indian built engine never had an O ring fitted. Fitting a fatter one is a tip from Sticky's manual and should seal better.
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Sticky says to use copper grease on the pivot pins and cam, but I only have Bendix high performance synthetic lubricate, so use that instead (oh, err...). I've cleaned up the old shoes and they're usable, but seeing as I'm fitting a new hub I'll order new shoes as well.
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Next fit the hub cone, not forgetting the shim and making sure the gap sits over a spline.
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I've bought a Casa Octopus Hub (the standard spline version). This came supplied with extra long studs, for use with an Octopus wheel rim (naturally), but I'm using the AF tubeless rim that came with the GP when supplied by Rayspeed. The Casa studs are too long. Shouldn't be a problem as you can just use four standard studs, in theory.
 Casa extra long stud v. new standard length |  Casa stud is too long |
The standard studs I have protrude too far though the hub though, and prevent the rim from sitting flat on the hub! Looking in a box of bits that Nicky picked up from the web I find an original stud, and you can see that the thread on my new one is at least 2mm too long. Ah the joys of maintaining machinery using basically cottage industry parts...
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Well a frustrating bitsa kind of a day, but I do end up with a list of parts to order from Steve. Inspecting the TS1 shows I also need new exhaust and inlet gaskets. I now have to face the fact that this engine will not be built and set-up prior to the all-inclusive rally in March. Time to put it aside and service my Jet instead. If you're going see you there. It should be a great weekend.
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