I unloaded it today and made room in the garage for it.
Fitted the starter clutch (already repaired) as the new chain had arrived.
The starter now works perfectly.
I had an 11 hour drive yesterday to collect this. Loud and proud.
I unloaded it today and made room in the garage for it.
Then I opened a parcel with new 750 parts in it so got to work on that.
Fitted the starter clutch (already repaired) as the new chain had arrived. The starter now works perfectly.
Also received new switchgear and cables for it. Happy days.
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It was a day of small things. Firstly I checked and adjusted set of carburettors. I replaced several rubbers and seals, set the float heights and visually balanced the carburettors by equalising the slide gap. The remit was to inspect and report back but I tidied up a few loose ends along the way. One of the mixture screws was seized solid and a screw had been snapped off. Then I started removing a seat cover. Before fitting the new cover I think I have to do some work on the foam as it has been cut down and lost it's shape. Finally I spent some more time filing the splines down on the 750 starter gear wheel as it was still a bit too tight to fit on the shaft. All sorted now, but waiting on the new chain before rebuilding it.
I have been busy doing other things the last few days. Yesterday I bought another project bike, Speed Fiber!
It has many broken parts, worn out parts, many parts are damaged or missing altogether. Perfect! I have a basic plan for it but that is still open to change. Watch this space, but don't expect anything soon. Today I was determined to remove the starter wheel on the 750. In the end I had to cut the chain off in order to make enough space for my puller. Even with the chain removed the gear wheel was very difficult to remove but eventually it yielded. The inner section of the starter clutch was then free to be removed from the crankshaft. As expected the rubber oil seal was brittle and broken so I have ordered another one, along with a new starter motor chain. That job should be finished in around a week's time when the parts arrive. With the starter clutch cleaned and the new springs fitted the whole assembly now works as it should. I then turned my attention to the Atlas. My painter had told me the new tank decals had turned up so I removed the tank and took it to him. While I waited the old decals were removed, the paintwork polished and the new decals fitted.
They really make the bike look a lot better. While the tank was removed I fitted new spark plugs and caps, and I cleaned the air filter at the same time. The bike is now up for sale so please look in my For Sale section for details. It was evident from attempts to start the 750 that the starter clutch was having problems gripping the crankshaft, resulting in failure to start easily. I ordered some new parts for the clutch, borrowed a special puller for the clutch and bought a new impact gun. This meant that I could undo the crank nut without having to lock the crankshaft. Primary cover removed, then crank nut and dynamo nut removed. Dynamo belt and pulleys removed. Starter clutch removed. The problem was easy to see. The rollers were out of position due to the springs having broken, plus an accumulation of dirt in the clutch area. Compare old and new springs. It was all going very smoothly until I tried to remove the starter sprocket as the chain needs to be removed to remove the centre of the clutch still attached to the crankshaft. I removed the circlip but the sprocket jammed and I will need time to work out a solution. So, I thoroughly cleaned the clutch and fitted new springs but can't re-fit it until I find a way to remove the sprocket. So, instead I fitted new tank badges and called it a day.
I had some niggly electrical issues to fix today, and it took all day to do it.
Yesterday everything worked but the right side indicators and the horns. It took a bit of fixing and in the end I had to replace a 6 pin connector block with a new one as it was stopping the pins making proper connections. I also looked at the left switchgear and removed the plastic sheathing in order to run a wire from the switch to earth as this was why the horns would not work. The Laverda ND switchgear runs the horn button to earth to make the horns activate, and without an adequate earth it was stopping them working. So, all is complete now and I can move on to the next problem. Plenty still to do but I will start with timing the ignition and replacing the cam chain and setting valve clearances. Beer o'clock now though! A day of finishing things off.
Connected the new ignition. Made up starter motor cables. Fitted the air filter box. Fitted the battery and strap. Connected all the remaining wires in the headlamp shell. Tested things all worked, just need to source a fault with the right side indicators. Tomorrow I can move on to other things at last. Successful but slow day today. Temperature didn't get above 4ºC in the cave so working with metal tools, small screws and thin wires was always going to be a royal pain.
Anyway, I managed to connect the coils, front brake switch and I made up a sub-loom for the horns. More or less just the wires in the headlamp shell to sort out, connect and time the new ignition system and make heavy duty cables for the starter motor and battery. Then I will be free of wiring with a bit of luck, and on to the brakes then. Slow progress. Main task today was to work out why the 6 pin connector from the left switchgear had to join to a 9 pin connector with 8 wires in it. This is the third brand new harness as the first 2 were for some other model. This harness looked correct but today I realised it was for a 120 Jota, not a series 2 180 Jota. Eventually I found that 2 of the wires were not required on this model so I removed them. This made things a lot simpler and it was an easy job to plug the 6 correct wires into a replacement 6 pin connector block. The right switchgear was straightforward and an easy connection (3 pin to 3 pin connectors). Most of the work today was looking at wiring diagrams and trying to solve the problems described. Tomorrow will be spent finalising the connections around the battery area and under the fuel tank. I will then start on the connections inside the headlamp shell and then it should be complete. Fingers crossed. After that I will have to connect the Witt system and time the engine. I am also looking for a new home for this 250 Ducati Scrambler. I collected it yesterday.
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