The cork washers for the primary foot peg stud, how may in total? There are two inside the chain case but should there also be one between the outside of the inner chain case and the sleeve for a total of three? There is a gap between the back of the chain case and the sleeve on my bike and am wondering if I am missing something?

The sleeve goes between the two parts of the primary, not behind it. So just one washer at each end of the sleeve inside the case. Total two, not three. We are all still learning.

If you haven't got one, download the BSA parts list from Draganfly it shows the original diagrams showing what goes where. I found it invaluable at times.

I have an original box full of these cork washers but they are to brittle to use.

Henk

email (option): ahum@quicknet.nl

Problem has been solved.

The inner chain case, front mounting bolts had in the past been over tightened so front of case now warped and not allowing case to move far enough to the right. Back of inner case where foot peg bolt passes through also bent inward so creating a 1/8" gap between it and spacer. So an hour later using sheet metal body tools and all dents and bent areas now straight. Put inner chain case back on and it now fits perfectly.

There should be two identical distance tubes #66-4903 one inside the chiancase and one behind it. otherwise it could scrunch out of shape. There are just two cork washers listed in the parts list #66-4902.

This is the drawing from my illustrated parts list and shows the parts 4 & 5. You can also see them in the drawing on the left which is shown from underneath the frame.

I have fitted the innermost spacer without removing the primary case if anyone wants to know how. Ron

email (option): ronpier@talk21.com

I fit the inner spacer and then a cork washer against the back of the inner cover...not forgetting the inner cover to crank case gasket when fitting the inner cover..

Next fit the primary drive and then fit the outer spacer with a cork fitted at the outer end...Finally replace the outer cover...

I generally apply silicone sealant to both corks on the side that faces the respective covers...

The spacer behind the inner cover is essential, along with the one inside, to support the cover assembly and to prevent distortion of the covers and contact with the clutch etc. when the footrest retaining nuts are tightened..Ian

email (option): ian@wright52.plus.com

Well, we do still learn. Apologies Bruce for incorrectly stating the spacer only went inside. Glad you got it sorted. This error was on my own experience that there is only the chaincase one on mine! In fairness to myself there hasn't been one there during my ownership so I never missed it! Knowing a tiny bit of its owner history I will stake money on it that it wasn't there for the previous two owners at least. Thankfully it hasn't caused any problems but I will have to get something sorted for whenever the case has to next come off. (Hangs head in shame)

My cases were somewhat beyond redemption so they got a nice big O ring.
Only hole on the entire bike ( including rider ) that does not leak.

email (option): bsansw1@tpg.com.au

OK, so one cork goes between outside of inner chain case and spacer and one cork goes inside chain case between spacer and outer cover? I thought both corks went inside chain case? One on either side of spacer???? Looks like I need to pull the inner cover back off if one cork is supposed to be on the outside.

So the order left to right is supposed to be:

Nut
Steel washer
Foot peg
outer cover
Cork washer
Spacer
Inner cover
Cork washer
Spacer
Foot peg mount
Engine plate

Is this correct?

Looking closely at the drawing I posted, I'm sure the way Ian has described it is correct, and as per your sequence! However I don't think I'd disturb anything if you have the clutch and primary side all set up. The cork washer will work just as well either side of the inner chain-case. From memory my own cork washers are both on the inside of the chain-case and no leaks, but something to address another time whenever I might have to work on the clutch. Ron

email (option): ronpier@talk21.com