Lightning rebuild

Benchracer1 · Jun 24, 2024

Morning guys. I'm new to this site. I have a friend who wants me to rebuild his 650 lightning motor. I've rebuilt chevy, dodge, vw and all the Japanese motorcycle. I am wondering if there is any black art to the British motor or if caution and a good manual will sofice? Also would be interested in which manual you guys recommend as well as a good machine shop and parts source.....Steve

AZMatt · Jun 24, 2024

I don't think it's a black art. The same attention to detail is needed as with any engine. The number 1 rule on British bike rebuilds is to clean the sludge trap in the crankshaft. The BSA service manual is great. Its available online for free on sites like Classic British Spares. Get a good set of Whitworth wrenches and sockets. Where are you located? I might be able to recommend a good machine shop.

marshg246 · Jun 24, 2024

Benchracer1 said:
Morning guys. I'm new to this site. I have a friend who wants me to rebuild his 650 lightning motor. I've rebuilt chevy, dodge, vw and all the Japanese motorcycle. I am wondering if there is any black art to the British motor or if caution and a good manual will sofice? Also would be interested in which manual you guys recommend as well as a good machine shop and parts source.....Steve

You can get factory workshop and other manuals here: https://classic-motorbikes.net/manuals/

baz · Jun 24, 2024

With an a65 motor the timing side bush fit to crank has to be perfect
This is the Achilles heel of the motor hence various conversions to needle roller main
But they can be ok as standard if built properly
And the oil is changed frequently

AZMatt · Jun 24, 2024

baz said:
With an a65 motor the timing side bush fit to crank has to be perfect
This is the Achilles heel of the motor hence various conversions to needle roller main
But they can be ok as standard if built properly
And the oil is changed frequently

I agree. This is very important on an A65. You need to measure the crank journal and the bushing to determine if its still in tolerance. If not, you need to have someone who knows this process do the machine work. It must be line bored so it is concentric with the bearing in the left hand case. Morrie's Place in Ringwood, Illinois is a good shop that knows how to do this.

Benchracer1 · Jun 26, 2024

I spoke with morries place. I'll be using them for parts and machine work. Thanks guys.

acadian · Jul 6, 2024

The TS bush has already been mentioned, I converted to the roller bearing and oil end feed, oil pressure with a new hepolite cast iron oil pump is rock solid 60-70 psi at speed, and 20 psi hot idle. Invest in a good oil pump regardless of what you do with the TS bush. Also pay attention to the gearbox, shimming the layshaft properly is critical as is ensuring full engagement between the gears and dogs. The cam plate should be renewed and all bearing surfaces on it polished. One last piece of advice, make sure ALL the outer case bolt hole threads are good while it's apart.

Benchracer1 · Jul 7, 2024

Thanx for the heads up. I'm going over to the guys house this week and look at it. Apparently it has a bad rod bearing

Benchracer1 · Jul 30, 2024

Well, I have the bike disassembled and it definitely has a bad rod bearing. Packaged up the affected engine components and sending them off to Morries place for the necessary machine work. While I'm waiting for that to be completed I am going through the rolling chassis. I'm going to change the steering head bearing(rust).I'd like to get a set of tapered roller bearings. Does any body have any recommendations for Amy particular brand?.....Steve

acadian · Aug 3, 2024

Benchracer1 said:
Well, I have the bike disassembled and it definitely has a bad rod bearing. Packaged up the affected engine components and sending them off to Morries place for the necessary machine work. While I'm waiting for that to be completed I am going through the rolling chassis. I'm going to change the steering head bearing(rust).I'd like to get a set of tapered roller bearings. Does any body have any recommendations for Amy particular brand?.....Steve

SRM sell a tapered bearing kit. Have a look at the swingarm bushings as well, you didn't say what year it is, may have silentbloc bushes. There are better options that require machine work depending on how far you want to go, I converted mine to oilite bronze bushings

Lightning rebuild

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