BritBike Forum logo
BritBike Sponsor BritBike Sponsor BritBike Sponsor
BritBike Sponsor

BritBike Sponsor

BritBike Sponsor
BritBike Sponsor BritBike Sponsor BritBike Sponsor
JRC Engineering dealers
Home | Sponsors, Newsletter | Regalia | Calendar | Bike Project | BritBike Museum | Spiders Cartoons, "OLD" BritBike Forum | DVD- Manuals & Parts books | BritBike Stickers & Decals
Upgrade to: Premium Membership | Premium Life Membership | Vendor Membership | Site Sponsor Membership
Member Spotlight
Kevin (NZ).
Kevin (NZ).
Christchurch, NZ
Posts: 1,799
Joined: August 2001
Show All Member Profiles 
Shout Box
Search eBay for motorcycle parts in following countries
Australia, Canada, France, Holland, Italy, United Kingdom, USA
Random Gallery photo
Who's Online Now
29 registered members (998John), 196 guests, and 443 spiders.
Key: Admin, Global Mod, Mod
Newest Members
Mickeyrat, Gtommy, Stew Dempsey, JoeBrown, Bart223
10176 Registered Users
Top Posters(30 Days)
Lannis 105
reverb 90
Stuart 68
koan58 68
L.A.B. 54
Popular Topics(Views)
555,042 mail-order LSR
Forum Statistics
Forums34
Topics66,612
Posts645,585
Members10,175
Most Online3,995
Feb 13th, 2017
Like BritBike.com on Facebook

Previous Thread
Next Thread
Print Thread
Rate Thread
BSA A65 crankshaft idler pinion removal #265908
07/20/09 7:58 pm
07/20/09 7:58 pm
Joined: May 2007
Posts: 14
South Wales
U
UNF Offline OP
BritBike Forum member
UNF  Offline OP
BritBike Forum member
U
Joined: May 2007
Posts: 14
South Wales
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
Support your #1 BSA Forum and our favorite sponsors

Check out BSA on e-bay: BSA Parts in UK, BSA Motorcycles in UK, BSA Parts in North America, BSA Motorcycles in North America

 
 
Re: BSA A65 crankshaft idler pinion removal [Re: UNF] #265912
07/20/09 8:25 pm
07/20/09 8:25 pm
Joined: Sep 2002
Posts: 7,813
Seattle
Alex Offline

BritBike Forum member
Alex  Offline

BritBike Forum member
Joined: Sep 2002
Posts: 7,813
Seattle
I use a puller kind of like this one:


I had to grind the tips of the jaws down a little bit to make it fit in the slots.


A smattering:
'53 Gold Flash
'67 Royal Star
'71 Rickman Metisse
'40 Silver Star
'37 Rudge Special
sixtyseventy Lightboltrocket road racer...and many more.
Re: BSA A65 crankshaft idler pinion removal [Re: Alex] #265929
07/20/09 9:53 pm
07/20/09 9:53 pm
Joined: Oct 2001
Posts: 529
Norway
Ola Offline
BritBike Forum member
Ola  Offline
BritBike Forum member
Joined: Oct 2001
Posts: 529
Norway
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)
Re: BSA A65 crankshaft idler pinion removal [Re: UNF] #266284
07/22/09 6:55 pm
07/22/09 6:55 pm
Joined: May 2007
Posts: 14
South Wales
U
UNF Offline OP
BritBike Forum member
UNF  Offline OP
BritBike Forum member
U
Joined: May 2007
Posts: 14
South Wales
Thanks for the feedback. Hopefully, one way or another I'll be able to get the pinion off!

Cheers,

UNF


'71 BSA A65 Lightning
Re: BSA A65 crankshaft idler pinion removal [Re: UNF] #266337
07/23/09 3:18 am
07/23/09 3:18 am
Joined: Dec 2002
Posts: 3,245
arkansas
L
leon bee Offline
BritBike Forum member
leon bee  Offline
BritBike Forum member
L
Joined: Dec 2002
Posts: 3,245
arkansas
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.

Re: BSA A65 crankshaft idler pinion removal [Re: leon bee] #266380
07/23/09 1:22 pm
07/23/09 1:22 pm
Joined: Sep 2002
Posts: 7,813
Seattle
Alex Offline

BritBike Forum member
Alex  Offline

BritBike Forum member
Joined: Sep 2002
Posts: 7,813
Seattle
Holy crap, I just now noticed that it only has one slot after Leon pointed it out. That's gonna make it kinda tough...kinda like the odd philips screw you get with no slots...


A smattering:
'53 Gold Flash
'67 Royal Star
'71 Rickman Metisse
'40 Silver Star
'37 Rudge Special
sixtyseventy Lightboltrocket road racer...and many more.
Re: BSA A65 crankshaft idler pinion removal [Re: Alex] #266402
07/23/09 3:10 pm
07/23/09 3:10 pm
Joined: Dec 2006
Posts: 51
sweden
nisse Offline
BritBike Forum member
nisse  Offline
BritBike Forum member
Joined: Dec 2006
Posts: 51
sweden
try to use a socket under a big screwdriver

Re: BSA A65 crankshaft idler pinion removal [Re: leon bee] #267146
07/28/09 3:10 am
07/28/09 3:10 am
Joined: Oct 2008
Posts: 4,947
Gnashville
DavidP Online content

BritBike Forum member
DavidP  Online Content

BritBike Forum member
Joined: Oct 2008
Posts: 4,947
Gnashville
Originally Posted By: leon bee
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"
Re: BSA A65 crankshaft idler pinion removal [Re: DavidP] #267157
07/28/09 3:44 am
07/28/09 3:44 am
Joined: Sep 2001
Posts: 2,792
Comox BC Canada
G
Gordo in Comox Offline
BritBike Forum member
Gordo in Comox  Offline
BritBike Forum member
G
Joined: Sep 2001
Posts: 2,792
Comox BC Canada
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!
Re: BSA A65 crankshaft idler pinion removal [Re: Gordo in Comox] #267163
07/28/09 4:10 am
07/28/09 4:10 am
Joined: Oct 2008
Posts: 4,947
Gnashville
DavidP Online content

BritBike Forum member
DavidP  Online Content

BritBike Forum member
Joined: Oct 2008
Posts: 4,947
Gnashville
Now I see what you're talking about. Shame this didn't come up last week when my timing side covers were off. I could've inspected.
Guess I'll find out this Winter when I need the cases open.


Stepping on others doesn't make you stand tall.

71 A65L "Zelda"
92 BMW K100rs "Gustav"
72 T120V cafe project "Mr. Jim"
Re: BSA A65 crankshaft idler pinion removal [Re: DavidP] #267195
07/28/09 11:36 am
07/28/09 11:36 am
Joined: Aug 2001
Posts: 3,881
Cape Carteret, NC
M
Mr Mike Offline
BritBike Forum member
Mr Mike  Offline
BritBike Forum member
M
Joined: Aug 2001
Posts: 3,881
Cape Carteret, NC
I use a puller just like the one Alex has pictured. I have ground the tips of the jaws to fit and hardened them for this application. I also take a large hose clamp and tighten it around the jaws so it won't slip off. It works every time to get this stubborn little gear off.

Mr Mike

Re: BSA A65 crankshaft idler pinion removal [Re: Mr Mike] #267385
07/29/09 6:17 am
07/29/09 6:17 am
Joined: May 2006
Posts: 68
FRANCE
S
SERGE A65 Offline
BritBike Forum member
SERGE A65  Offline
BritBike Forum member
S
Joined: May 2006
Posts: 68
FRANCE
This pinion is sometimes difficult to extract. It is possible to heat it slightly, but you should still use a strong puller. If you can weld, this puller will not cost you anything, and you'll enjoy using your own tool. When the puller is clamped, it is impossible that it breaks. Needless to heat.



1965 A65 STAR
1968 A65 LIGHTNING
Re: BSA A65 crankshaft idler pinion removal [Re: SERGE A65] #267391
07/29/09 6:58 am
07/29/09 6:58 am
Joined: Dec 2002
Posts: 3,245
arkansas
L
leon bee Offline
BritBike Forum member
leon bee  Offline
BritBike Forum member
L
Joined: Dec 2002
Posts: 3,245
arkansas
Mr Mike and Serge have both skipped over the fact that little gear only seems to have one slot in it.

Re: BSA A65 crankshaft idler pinion removal [Re: leon bee] #267428
07/29/09 12:04 pm
07/29/09 12:04 pm
Joined: Aug 2001
Posts: 3,881
Cape Carteret, NC
M
Mr Mike Offline
BritBike Forum member
Mr Mike  Offline
BritBike Forum member
M
Joined: Aug 2001
Posts: 3,881
Cape Carteret, NC
Leon, or Winslow if I recall...you are right. I went back thru the thread and it appears that one slot is missing. Gotto go to the heat and screwdriver method and hope I. For most of us that have the two slots, a simple modification to in inexpensive two jaw puller and a hose clamp really work wonders. I put a little tension on it and then just warm it with the tip of a small butylene torch ond off she comes.

Mr Mike

Re: BSA A65 crankshaft idler pinion removal [Re: Mr Mike] #267440
07/29/09 12:56 pm
07/29/09 12:56 pm
Joined: Sep 2002
Posts: 7,813
Seattle
Alex Offline

BritBike Forum member
Alex  Offline

BritBike Forum member
Joined: Sep 2002
Posts: 7,813
Seattle
If it doesn't come off easily by prying, don't much up your cases. Extract the oil pump studs and use one of these bearing pullers:


A smattering:
'53 Gold Flash
'67 Royal Star
'71 Rickman Metisse
'40 Silver Star
'37 Rudge Special
sixtyseventy Lightboltrocket road racer...and many more.
Re: BSA A65 crankshaft idler pinion removal [Re: Alex] #267470
07/29/09 2:44 pm
07/29/09 2:44 pm
Joined: May 2006
Posts: 68
FRANCE
S
SERGE A65 Offline
BritBike Forum member
SERGE A65  Offline
BritBike Forum member
S
Joined: May 2006
Posts: 68
FRANCE
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
Re: BSA A65 crankshaft idler pinion removal [Re: SERGE A65] #267556
07/29/09 8:57 pm
07/29/09 8:57 pm
Joined: Jul 2007
Posts: 529
Wollaston Northants
kelvin Offline
BritBike Forum member
kelvin  Offline
BritBike Forum member
Joined: Jul 2007
Posts: 529
Wollaston Northants
Why don't you continue to split the cases leaving the crank and this gear where it is.
Once they are split with some help holding the half case hit the
end of the crank with a rubber or copper mallet.
Or a block of timber and a hammer. Good luck.
Where thers a will thers a Way. Kelvin.

Re: BSA A65 crankshaft idler pinion removal [Re: kelvin] #267667
07/30/09 12:52 pm
07/30/09 12:52 pm
Joined: Aug 2001
Posts: 3,881
Cape Carteret, NC
M
Mr Mike Offline
BritBike Forum member
Mr Mike  Offline
BritBike Forum member
M
Joined: Aug 2001
Posts: 3,881
Cape Carteret, NC
Kelvin,
You run great risk in damaging something else, by beating out the crank. Methods suggested should get it done. The bearing or gear pullers posted by Alex are handy and the come in a wide range of sizes but most of us don't have them in our shops as they are infrequently needed. Over the yeas I have made a few tools for specific task on BSA's and the special puller for this job was easy and works well...if you have the two slots on the gear like it is supposed to be.

Mr Mike

Re: BSA A65 crankshaft idler pinion removal [Re: DavidP] #267864
07/31/09 1:35 pm
07/31/09 1:35 pm
Joined: May 2007
Posts: 14
South Wales
U
UNF Offline OP
BritBike Forum member
UNF  Offline OP
BritBike Forum member
U
Joined: May 2007
Posts: 14
South Wales
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
Re: BSA A65 crankshaft idler pinion removal [Re: UNF] #324846
07/26/10 8:00 am
07/26/10 8:00 am
Joined: Jul 2010
Posts: 1
Alberta, Canada
JohnTaylor Offline
One time poster
JohnTaylor  Offline
One time poster
Joined: Jul 2010
Posts: 1
Alberta, Canada
I have mine off, any advice on getting it back on without upsetting anything?

Cheers!


72 BSA Lightning
Re: BSA A65 crankshaft idler pinion removal [Re: JohnTaylor] #324967
07/27/10 1:42 am
07/27/10 1:42 am
Joined: Dec 2002
Posts: 3,245
arkansas
L
leon bee Offline
BritBike Forum member
leon bee  Offline
BritBike Forum member
L
Joined: Dec 2002
Posts: 3,245
arkansas
Tap, tap, tap, put a deepwell socket over it. They go back on pretty easy, make sure the key fits nice.

Re: BSA A65 crankshaft idler pinion removal [Re: UNF] #637130
01/26/16 3:58 am
01/26/16 3:58 am
Joined: Oct 2014
Posts: 3
Wisconsin, USA
R
Roop Gill Offline
BritBike Forum member
Roop Gill  Offline
BritBike Forum member
R
Joined: Oct 2014
Posts: 3
Wisconsin, USA
Here is my recent project picture: pinion came off easy with this setup.



1952 BSA A10
1948 Matchless G80
1968 Enfield Interceptor
1936 BSA G14

Moderated by  Allan Gill, Jon W. Whitley 


Home | Sponsors | Newsletter | Regalia | Calendar | Bike Project | BritBike Museum | Spiders Cartoons | "OLD" BritBike Forum | DVD- Manuals & Parts books | BritBike Stickers & Decals
Upgrade to: Premium Membership | Premium Life Membership | Vendor Membership | Site Sponsor Membership
Powered by UBB.threads™ PHP Forum Software 7.6.1.1
(Release build 20180111)
Page Time: 0.802s Queries: 15 (0.011s) Memory: 1.1586 MB (Peak: 1.4670 MB) Zlib disabled. Server Time: 2018-04-27 06:56:50 UTC