Sunbeam S7 Deluxe

[jpmillermatic]

thanks for sharing all this info....its waaaaaay outside my experience and understanding, but is very informational. Im sure you will get there in the end.

one thousandth at a time!

JP

 

[Shox Dr]

Been slowly munching away at stuff. Finally (mk3) got the timing pinion machined and pressed in. Oilite bearing required re-reaming to 19.50mm
I myst have got a dim wrong as the circlip backing washer covered the grove. Its hardened so annealed and machined down. It would have been a mare to clock in the 4jaw, so a bit of aluminium tube was rebated to size, with a m6 bolt to hold the washer. ID opened up and rebated to take circlip. Reheat and a dunk in oil, hard as nails again






The studs holding the rear bearing carrier have been happy not moving while I’ve been checking end float for a shim.

0.525mm. Note the angled face on the parting tool, breaks through on the right, nice clean cut on the shim off, with very little clean up.)

As soon as its final torque on the carrier, 2 studs decide to strip.

More kit to buy, once you need more than 2 sizes, is worth spending a bit more and get a set of 5
No 1/2" on the bike but the rest are.



Ready for the head to go on now, once I’ve annealed the h/gasket

 

[jpmillermatic]

I just had to use a thread repair kit on a VW B6 head for a cam chain cover bolt...stripped out as I was installing the cover....now, its better than new!...I love those things.

JP

 

[Dogruffracing]

Great work, I love these sunbeams they just look fantastic.

I have a 400/4 to restore at some point that my dad has owned since 1980 when it was 2 years old.

 

[Shox Dr]

Great work, I love these sunbeams they just look fantastic.

I have a 400/4 to restore at some point that my dad has owned since 1980 when it was 2 years old.

I do like 400/4s, a lass I know from Howden has one

Cheers, Its almost ready to go in the frame, just waiting on a clutch, and a new set of pipes

 

[Shox Dr]

Arrrrrrrrrrh!

[several weeks earlier]

Decided to have the clutch relined. Asked for a ‘soft’ compound, I did comment it looked fluffy when I picked it up.

Anyhooos, it **** its brains today


Looks like Ive stashed a load of weed in there


Oh its back in the frame, few oul leaks, not charging at first, and vibration that was there before the rebuild. Returned out to be poor voltage to the coil, soon as it was chaging, vibrating gone.

It rode beautifully until the clutch nipped up

 

[jpmillermatic]

That is certainly a SOFT compound!....I didnt know hemp was a viable clutch surface!




JP

 

[Wallace]

That helicoil kit looks the same as a metric kit I have, the first one I did the insert tool ended up wedged in tight as it was bigger than the core diameter and some of my inserts of one particular size have proved almost impossible to fit, I hope yours is better. The clutch friction material looks like hessian sacking!

 

[Shox Dr]

Yes very strange looking stuff, never seen a clutch like it

Not looked at it since Saturday. Today I’ll pull it out .... again. Hopefully its not warped the plates

 

[8ob]

Yes very strange looking stuff, never seen a clutch like it

Not looked at it since Saturday. Today I’ll pull it out .... again. Hopefully its not warped the plates

Mr Shox are you sure its not the plates that have eaten the clutch

Bob

 

[lchris21]

Apologies........cant believe I missed this. Just had a read through. ............Great work going on, Im in.......too many threads too many forums

 

[Greeves246]

Some years ago there were fake Honda ( looked to be genuine Honda box and part no ) motorcycle brake pads coming into the country that apparently consisted of grass and cement!

 

[8ob]

Apologies........cant believe I missed this. Just had a read through. ............Great work going on, Im in.......too many threads too many forums

I have had many a " how the hell did I miss this" moment on here

Bob

 

[Shox Dr]

Mr Shox are you sure its not the plates that have eaten the clutch

Bob

possibly, I checked the plates before refitting, both were in good condition; flat with no hot spots or wear.

Clutch came from my local indy motorfactors, I’ve had many clutches from over the yrs, never a problem, so it could well be the plates. I’ll ring Stewart Engineering and see what Rob has to say.

If I didn't know better you’d swear a mouse had made its home


As you can see, not a lot left. Plates are now warped and scored

 

[Shox Dr]

Looks like a miscommunication between myself the motorfactors and the clutch guys.

Never mind. If there’s ever a competition for the fastest removal of a Sunbeam engine. I reckon I have a chance... took less than 40mins from loosening the first nut to the engine and gearbox on the floor. 10 of that was building the cahonas to lift out

 

[Farside]

Looks like a miscommunication between myself the motorfactors and the clutch guys.

Hm... I wonder how "I'd like a soft clutch plate for my elderly motorcycle" got construed as, "please make me a grass clutch plate."

 

[Shox Dr]

Hm... I wonder how "I'd like a soft clutch plate for my elderly motorcycle" got construed as, "please make me a grass clutch plate."

Yeah that was pointed out. I’ve no doubt he’ll sort it out

 

[Wallace]

I just remembered my Father complaining about clutch slip with me on back of his knackered S8 as a teenager! It must have been on the rivets as it was a git to start and you could hear the compression leaking kicking it over.

Edit: It was still alive in 2011

 

[Shox Dr]

While the engine is out again. Its a good time to finally [hopefully] get rid of a gearbox leak on the clutch pushrod assembly. Originally fitted with just an Oilite bearing, it’s worn and is letting oil past. Total PITA getting it out. Had to cut a slit with a hacksaw blade as it would not come out with a slide hammer.


There’s not enough wall thickness to rebate for a seal, luckily a BS018 O-ring fits the bill.


Loctited in


Hopefully one less drip

 

[Shox Dr]

Thought I’d find out how much the reserve holds. Measured in Sparrows Bladders it holds exactly 2 and twevety seventeens (Thats it in the bottom of a 2pint jug)


.... tap sits in a rebate the upper pipe is level this the bottom of the tank, the lower hole just gets rid of the dreg

Meanwhile the gearbox has decided to start weeping from the side plate it had been gobbed on with something, and was a total pain to get off, I thought just Wellseal would do the job, I need access as the kick start splines are worn, also I might need in to replace the kick start quadrant. So need it to be easily removed. Best make a gasket. My usual gasket paper is .75mm thick, too thick; it’ll pul the quadrant out of mesh (to much), a bit of a mooch and the cover from a school book is perfect at .25mm.



Next up an annoying rattle, I think its the front pivot bush for the seat, you can see where the movement has marred the threads. Machined a new one from Acetal