69 BSA bobber project...or...the cure for wintertime madness!

Discussion in 'Some Assembly Required' started by YZman, Feb 8, 2009.

  1. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

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    Thanks for posting this YZman. It brings back memories of my old 69 BSA. (650 Lightning, bored and stroked to 750)

    It was a nice bike, and very fast, but VERY expensive to keep it going (mid 80's and no interwebz).

    Lately, I have had thoughts about going back out to AZ and getting it back, since I know the guy I traded it to still has it, but it has been sitting outside for 20 years now, and I could never justify the cost to get it going again.

    I wish you the best with it. Enjoy it when you're finished, you deserve it!

    Oh, BTW, watch that gas tank. Those old BSA tanks have a way of coming apart at the seam! Going down the road at 80+ with a split tank, getting soaked with gas, and having 50 miles to get home is no fun! I never could get it fixed right, and ended up putting a 3 gallon Kawi tank on it.

    :1drink
  2. Packer

    Packer Been here awhile

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    Good job you're doing there YZman. I found this thread yesterday and thought that with a start date of '09 it would be long finished by now:D Life has kind of got it the way, I hope that the future is looking brighter now.

    You are probably aware that most of fthe issues with these old BSA 650's were down to axial movement in the crank causing bottom end lubrication problems. You referred to a "shim kit" that you got from Ed the engine man which may be an issue down the road. If you have a roller primary side bearing and a bush timing side the thin shims that BSA used can cause issues and a custom one pice shim in place of a stack of thin ones is considered the simplest way forward. Have you seen this thread? http://www.piled-arms.com/tech31.html

    Apologies in advance if I'm preaching.
  3. YZman

    YZman Bouncing off Trees

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    Good stuff man. Thanks for the link. Yea I was aware of some of that but its always good to read up more on it. Almost makes me want to tear my motor back apart just to check the end play :lol3
  4. Packer

    Packer Been here awhile

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    Just make sure that the alternator rotor is properly tightened, loctited, dot peened, tab washer.............:D

    I wonder if it is possible to temporarily hook up an oil pressure gauge to the sensor tapping on the crankcase as soon as the bike is ready to run. Record the pressure readings, oil spec, temperature etc. Repeat after 3,000 miles and compare. It might act as an early warning of problems without needing to strip the engine down.
  5. YZman

    YZman Bouncing off Trees

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    Ok. Finially have something worth posting. Been working on the wireing every little chance I get. Had to order up a few parts from Mcmaster Carr, bolts, spacers, grommets. Stuff like that. But I think I pretty much have everything I need to finish the wireing....except time that is. Seem to be lacking a lot of that this winter..

    Have managed to do a little work in my shop getting it all setup the way I want it. Just bougth my 1st bench vice ever. And got some aluminum soft jaws for it

    [​IMG]
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    Anyways. Started making some wires up.

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    Ignition switch all wired up and ready

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    Drilled a hole in the back of the frame where the tailight wires will run thru

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    And another for the tailight wires to come out of. There already was that big hole in the back of the frame backbone, probably for water drainage during the painting process. Will work great for running wires up to the front of the bike

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    And up at the front of the bike the wires will come out here

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    Thats about it for now. Doesnt look like much but that took a lot of brain power to make the decisions of where to drill those holes, ok maybe i was a little scared to drill them... it is the frame after all :lol3

    So this week I have to drill one more 3/4" hole up front, dont have a drill for that so I have to grab one from work tomorrow. Once that is done I can lay down the rest of the wires. Hopefully this week Ill make some real headway on the wireing. Cause next week I am headin to the Nuclear Cowboyz show and then flyin to Florida for some R&R.
  6. YZman

    YZman Bouncing off Trees

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    Fun with wire!

    [​IMG]
  7. Hughlysses

    Hughlysses Long timer

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    Nice work! :clap
  8. YZman

    YZman Bouncing off Trees

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    Also bought some 1/4" spacers to space the electronics off the mounting panel. My origional thought was mainly because I wanted to run some wires up behind those boxs up to the frame above. But as it turns out its turning into a great place to hide some wire connections. I hate having big bundles of wires and connectors visable. Im trying to hide all the connections I can (within reason) The 2 grommets I added to run the coil wires thru are directly behind the boxs and wont be visable at all from the back. The way the frame tubes run around the sides of that mounting panel you wont even notice that there is wires behind there. Nice and clean.

    [​IMG]
  9. YZman

    YZman Bouncing off Trees

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    Santa finally found his way to the new house. Better late than never. Too bad he forgot to give me the brackets to mount the side case to the main case. Damn elves anyways.

    [​IMG]
  10. Packer

    Packer Been here awhile

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    Are you trying to keep us on the edge of our seats with these little teasers?

    Should you have drilled the frame? How will you keep the oil in now, silicone around the grommets?:wink:

    A good looking tool box by the way, all of my tools would fit in the little side cabinet:cry
  11. YZman

    YZman Bouncing off Trees

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    Ill have to keep ya on the edge of your seat for a little anyways. Im in Florida this week.

    The older Bsa`s didn't have oil in the frames. They didn't start doing that till 1970 I think. More concerned with keeping it in the motor. They do have a reputation of being leakers.

    Yea that tool box is bigger than I need for now. But I will get more tools over time. Would rather get the extra room the 1st. time
  12. Packer

    Packer Been here awhile

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    I know, hence the :wink: smiley, my poor attempt at humour. That black tank on the right side of tthe frame in the early pictures was also a bit of a clue:D

    A lot of he leaks were the primary chain case seams, I believe that most of it was caused by DIY owners over tightening the bolts. Perhaps there is a belt conversion that you can use that will at least solve that issue.

    Enjoy Florida, hopefully sunny and warm.
  13. YZman

    YZman Bouncing off Trees

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    Yea. I've seen those belt conversions. But they are upwards of $1000. Way out of my budget. At least for now. That might be a project for another year. Gotta get it running and on the road 1st.

    Last day of Florida then we are heading home to the cold. Not looking forward to it.
  14. tex_downey

    tex_downey Been here awhile

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    eh your in MI.

    I came back from CA to IA and was shocked how easy this winter has been. :clap
  15. Floyd_ca

    Floyd_ca Stranger

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    I'm excited to see the girl up and running..... Your thread may owe my boss a good day of work..... Hope you can get her on the road this spring!!
  16. YZman

    YZman Bouncing off Trees

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    I dont think Ive ever used the words good day and work in the same sentance before..:lol3

    Back from Vacation. Did a little work on the wireing. But mostly been busy finding all my tools that are scattered between 3 differant portable tool boxs, several cardboard boxs, the misc cubbies of my truck and motorcycle trailer...take all those tools and arrange them in my new tool box. And in the process of taking inventory of my wrenches made a list of missing sockets and wrenches Il be needing to replace...Hmmmm might have to make a visit to the tool store then.

    Wireing has been a little fustrating. Not the wireing itself but running it thru the frame. Actually running it thru the frame is easy. But every time I think I have my grommet sizes figured out I realize I need to get bigger grommets. then I need a way to drill a bigger hole for said grommets. My drills only go to 1/2". No one around here sells a very good grommet selection so its back to Mcmaster Carr for a bag of 100 grommmets plus shipping for the 1-2 grommets that I need for the job. At least Ill have spares huh... :lol3
  17. Packer

    Packer Been here awhile

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    Use one of these:-

    [​IMG]

    a tapered hole cutter or get a stepped shank drill if the chuck size is a problem.

    Just think of all the grommets you'll be able to give to worthy causes:wink:

    Keep up the good work!
  18. YZman

    YZman Bouncing off Trees

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    Yep. Thats kinda what we have at work. Ive already borrowed it once.

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    Wasnt real impressed with the hole it cuts. But it got the job done. Still had to grind a massive burr off the back side though.

    have managed to get a little organized last night.

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    Still have a little ways to go

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  19. Packer

    Packer Been here awhile

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    If you're anything like me that degree of tidyness will last about a week:D
  20. pennswoodsed

    pennswoodsed lizards,bugs and me

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    let's not be rash !