The start of a new project !

[nairb]

Well we have to start somewhere.  Its very complete which is a change.  I have not heard it running.  I know there are some issues to fix …. like the starter clutch is slipping and the brakes need sorting.  Most of the electrics are working.  The oil was very clean.

Here is a pic.

As usual with my new projects I take most bits off the bike to check and re-grease if needed.  So-far its looking good.  The exhausts will need attention and hopefully they can be rescued.

Some parts are very dull and need a good polish, as usual with a machine of this age.

I am surprised to find most bolt heads and those chain adjusters are particularly dull.  They dont look like chrome plate.

My question is what are they plated with?.  It looks like zinc.  It come off with acid.  Does anybody know what it is.

I am Tempted to have those chain adjusters re-chromed.  But they were not chrome originally?.

Ta

Nairb

[Kaptainkwak]

I believe they are zinc plated, including the chain adjusters which if you intend to restore is good for you as zinc plating is far cheaper than chroming.

[nairb]

Thanks Kaptain.  I was surprised that they were Zinc plated.  In fact most things seem to be.  Well they have all been de-zinced, polished and sent to the Zinc platers.  37 bits all re-zinced for 20 quid.  Much quicker and cheaper than chrome plating.

I know I need to fix the starter clutch.  I have not tried it yet.

Are those “Starter Clutch Repair Kits” off ebay OK to try.   Just thought I would ask before getting one

Nairb

 

 

[Kaptainkwak]

It is much cheaper and easier. You can give zinc a very light buff to shine if you want to.

I can supply starter clutch repair kits. I have a great relationship with Zpower so if I don’t have it here I can usually get it there. Just let me know.

KK

[nairb]

So, a new discovery.  Those fork caps.  I thought they would be steel and chrome.  Mine are not rusty, just dull and scruffy.  So I took them off for a clean.

I guess they are an alloy with chrome?.  Anyway, not being rusty is a bonus, and they have gone back on a bit brighter/cleaner.

It’s only a small thing and for a change does not cost a fortune to fix.

[nairb]

The bike was bought as a non-runner…… so there had to be a reason? – right.  Sometime its just lack of use and stands in the shed for years.  But this bike was complete and turned over with compression.  All the electrics worked except the starter system.

“The starter clutch needs fixing” said the PO.  Fair enough, I thought.

So I have had a look before buying the necessary starter bits.  Oh dear.  Somebody had put the rotor back on and hammered it into place.  The woodruff key was not in the right place.  There are bits of metal and a poor looking rotor.  The actual starter bits still look OK.

Is it possible to buy a woodruff key?…… but I expect the rotor is all churned up and beyond fixing.

This is bike restoring.

Anyway, the exhausts were at a specialist being fixed until they rang up to say they were beyond repair.  I suspect they could not be bothered….. maybe.  So that’s become another issue

Onwards.

[nairb]

Just an update….. I finally looked at the end of the crankshaft where the rotor is held in place by the woodruff key… its all been cut away, or broken away.

So, that’s the electric start done for at least.  Maybe it can be tightened up enough for the generator to still work.

Hopefully the engine is ok……

[Kaptainkwak]

Hi Nairb

Firstly we are here to help. There is NO woodruff key on the crank. The generator assembly simply locks itself on the taper of the crank. I am unsure exactly what you are looking at.

I have many spares here and i am sure i can help you out.

Is yours a B1/B2 model? looks B2 to me Was it the original exhaust you tried to get repaired? They normally only lasted 2 or 3 years.

I have sent you my number in a PM.

Cheers

KK

[nairb]

Thanks KK.  I will phone this week.  “NO woodruff key on the crank”  Than explains why I could not find one on the parts diagram.

Here are some pics.

The Rotor

The brass insert and the metal bit were in the rotor.

The crank end

It looked like this was where the woodruff key was supposed to go.

The rotor is a bit churned up and might need replacing.

[nairb]

Here is a better pic of the rotor

and another view.

[Kaptainkwak]

I am really confused what is going on there. The starter clutch and generator do not have a brass spacer or a key of any description. It looks like for whatever reason a previous owner has somehow attempted to carry out a modification but to what and why? Looking at the pictures I feel the crank is still capable of locking the correct generator assembly on the taper as designed to do. If this won’t work with the generator you have this could be for 2 reasons.
1. The generator is not the correct one for the crank.
2. The generator body has also been modified/butchered.
Let us know what you find.

KK

[nairb]

A quick update.  Thanks KK I will phone this week.  Here are some pics.  “NO woodruff key” now that make a lot of sense.  There was non shown on the parts diagram.

Some pics…..

The inside of the rotor is a bit messed up.  The brass thing and the bit of metal was jammed in there.

The end of the crankshaft where I thought the woodruff key might/should have been.  The spring washer was also used.

Another pic of the inside of the rotor.  Somebody tried to create a woodruff key slot.

I might need a replacement rotor.

Yes, the exhausts are the originals.  They look alright(ish) when on the bike.  I have not given up on them yet, but maybe they are scrap.

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