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BSA A65 crankshaft idler pinion removal
#265908
07/20/09 7:58 pm
07/20/09 7:58 pm
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Joined: May 2007
Posts: 14 South Wales
UNF
OP
BritBike Forum member
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OP
BritBike Forum member
Joined: May 2007
Posts: 14
South Wales
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Hi, Need some advice on removing the crankshaft idler pinion on my A65 lightning 71' engine. The user manual advises that BSA extractor tool 61-3676 should be used, but what I'm not sure about is whether this is just a small puller or some special tool. Also, the pinion only has one machined slot (see picture), so I'm not sure if a puller will work.  Cheers, UNF
'71 BSA A65 Lightning
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Re: BSA A65 crankshaft idler pinion removal
[Re: Alex]
#265929
07/20/09 9:53 pm
07/20/09 9:53 pm
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Joined: Oct 2001
Posts: 529 Norway
Ola
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BritBike Forum member
Joined: Oct 2001
Posts: 529
Norway
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The idler gear needs some kind of a puller, the gear on your picture however will usually get off with the aid of two suitable screwdrivers. If still stuck, try a little heat.
Best regards
There are no bosses in a technical discussion (Doug Hele, 1919 - 2001)
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Re: BSA A65 crankshaft idler pinion removal
[Re: UNF]
#266284
07/22/09 6:55 pm
07/22/09 6:55 pm
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Joined: May 2007
Posts: 14 South Wales
UNF
OP
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OP
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South Wales
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Thanks for the feedback. Hopefully, one way or another I'll be able to get the pinion off!
Cheers,
UNF
'71 BSA A65 Lightning
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Re: BSA A65 crankshaft idler pinion removal
[Re: leon bee]
#267146
07/28/09 3:10 am
07/28/09 3:10 am
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Joined: Oct 2008
Posts: 4,947 Gnashville
DavidP

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Joined: Oct 2008
Posts: 4,947
Gnashville
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That's the first one I've seen that just has one slot. I wonder if you could cut another slot with a die grinder/dremel. If its on there real tight, the large screwdriver method can be kinda ugly. Maybe I'm not sure what y'all mean, but my 71 parts book shows only one keyway and one "slot" in the crankshaft. In any case, , I'd use two Wonderbars to ease the gear off the shaft, at least until you have enough space behind the gear to use a gear puller.
Stepping on others doesn't make you stand tall.
71 A65L "Zelda" 92 BMW K100rs "Gustav" 72 T120V cafe project "Mr. Jim"
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Re: BSA A65 crankshaft idler pinion removal
[Re: DavidP]
#267157
07/28/09 3:44 am
07/28/09 3:44 am
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Joined: Sep 2001
Posts: 2,792 Comox BC Canada
Gordo in Comox
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Posts: 2,792
Comox BC Canada
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I don't think we are talking about the crank keyway. I think the 'slots' are the grooves for use with a puller. This shot shows the top groove reasonably well and the bottom groove if you really look. I have never seen this gear with only one slot for pulling it off. Gordo 
Without frequent roadside repairs there is no fun in riding!
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Re: BSA A65 crankshaft idler pinion removal
[Re: Alex]
#267470
07/29/09 2:44 pm
07/29/09 2:44 pm
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Joined: May 2006
Posts: 68 FRANCE
SERGE A65
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BritBike Forum member
Joined: May 2006
Posts: 68
FRANCE
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This is an obvious manufacturing error. I have a dozen engines from 1962 to 1970. Everyone has a pinion with two slots. In such a case, do not hesitate to machine a second slot, using a grinder equipped with a narrow disk. These slots are the best solution to remove the pinion without risk for the cranckcase and sprocket teeth.
1965 A65 STAR 1968 A65 LIGHTNING
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Re: BSA A65 crankshaft idler pinion removal
[Re: DavidP]
#267864
07/31/09 1:35 pm
07/31/09 1:35 pm
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Joined: May 2007
Posts: 14 South Wales
UNF
OP
BritBike Forum member
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OP
BritBike Forum member
Joined: May 2007
Posts: 14
South Wales
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Hi all, Well, I took a chance and knocked the crankshaft through the casing, with a rubber mallet I might add. No damage to crankshaft assembly and pinion, but the plain bearing got a bit scored. I was intending to replace this, but obviously will have to now! Next task: remove the pinion. New slot 180 degrees opposed to the existing one is the option I'll investigate first.   Thanks for all the feedback. Cheers, UNF
'71 BSA A65 Lightning
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Re: BSA A65 crankshaft idler pinion removal
[Re: UNF]
#324846
07/26/10 8:00 am
07/26/10 8:00 am
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Joined: Jul 2010
Posts: 1 Alberta, Canada
JohnTaylor
One time poster
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One time poster
Joined: Jul 2010
Posts: 1
Alberta, Canada
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I have mine off, any advice on getting it back on without upsetting anything?
Cheers!
72 BSA Lightning
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