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Makotosun

AT1 rebuild extra parts after rebuild ?

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Replied by Ht1kid on topic AT1 rebuild extra parts after rebuild ?

MarkT don’t you think we should know if the right case has been changed   Dickdirty could you tell us which case you have from the enclosed picture 
30 Oct 2022 09:38 #11

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Replied by MarkT on topic AT1 rebuild extra parts after rebuild ?

Hmmm.. I'm not sure case would make a difference?

Only right side case change I can recall in the 69-73 era was when they went to a larger OD needle bearing on the output shaft... the bearing behind the kick idler gear went from 22 to 23mm OD.

P.S. the only reason I have some experience with this topic was I closely studied the transmission and clutch changes over the years (69-81) when I was installing a 6 speed trans in one of my CT1's.
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
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30 Oct 2022 10:36 #12

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Replied by Ht1kid on topic AT1 rebuild extra parts after rebuild ?

MarkT I do know of a change to the kick starter right case and the kick idler gear. I would like to hear how your 6 speed worked sounds awesome 

picture1 is the new version 
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Last edit: 30 Oct 2022 12:44 by Ht1kid.
30 Oct 2022 12:42 #13

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Replied by MarkT on topic AT1 rebuild extra parts after rebuild ?

I've looked at those pictures and can't really see any significant differences in the cases. What is the difference? 

The six speed is still more of a concept...  It seems to shift on the bench just fine but I'm not confident about the shimming of the gearsets or my manufacture/shimming of the shift drum.  I'd hate to have it try to engage two gears under power. 

I'd like to rig up a camera to see inside with cases bolted together or was thinking of sacrificing a set of bad cases by cutting windows in them.  I just don't have a set of bad cases LOL

I'll get back to it someday...  I don't have the space to work on it right now. 
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
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30 Oct 2022 17:53 #14

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Replied by Ht1kid on topic AT1 rebuild extra parts after rebuild ?

Hey MarkT the difference is the kick starter and idler are different the newer idler has different teeth count and a little thicker gear so if he has the older style case it would be 2 thrust washers as you said. Compare the kick start area and you should see the difference 

I may have a few cases you can have for free for your project.  Good Luck. 

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30 Oct 2022 22:08 #15

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Replied by dickdirty on topic AT1 rebuild extra parts after rebuild ?

Here are some pictures of the engine serial number, the rotational scraping on the inside of the crank case cover (which I believe is due to the 2nd washer), and some wear in the backside of the clutch assembly from the kick pinion gear (also due to 2nd washer?)
03 Nov 2022 15:33 #16

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Replied by dickdirty on topic AT1 rebuild extra parts after rebuild ?

Here are pics of the gear alignments with 1 washer and 2

As you can see the gears are much more aligned with only 1 washer.
03 Nov 2022 15:37 #17

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Replied by Ht1kid on topic AT1 rebuild extra parts after rebuild ?

How many teeth are there on your kick idler 
03 Nov 2022 17:00 #18

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Replied by MarkT on topic AT1 rebuild extra parts after rebuild ?

I'd be interested too.... I thought kick idler had same tooth count from 69-81... but wouldn't be first time I was wrong.

Anyway... I'm pretty sure your bike blew the kick gear under the clutch at some point and it was replaced with the taller revised 72-73 gear. The 2mm thick washer should then be removed..
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
03 Nov 2022 20:44 #19

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Replied by Ht1kid on topic AT1 rebuild extra parts after rebuild ?

26 Tooth picture 1 early.  27 tooth picture 2 late the different cases 
03 Nov 2022 22:14 #20

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