Topic: 750K2 Hot Rod Revival - Early Christmas

[MCRider]

I'll be danged.

[CBJoe]

I'll be danged.

Whelp....don't be too danged   I was totally wrong.  I was just out in the garage and when I pulled out the reduction gear it became apparent it was a trick of the light and the taper at the end of the gear.  There are no broken teeth.....stupid Joe.  This at least means that I don't have to fish around for broken bits.



However...since the rotor bolt isn't loose, I assume this means the rollers in the starter clutch need replaced.  I've got the puller ordered to remove the rotor and starter clutch.

Cheers, Joe

[754]

Examine that snout that the rollers grab on for wear and roughness.
Sad to say but the parts in these motors only last for 35 or 40 years...

[CBJoe]

Examine that snout that the rollers grab on for wear and roughness.
Sad to say but the parts in these motors only last for 35 or 40 years...

Thanks Frank...yeah.  Was just doing some searching and found the following  http://forums.sohc4.net/index.php?topic=165124.0  Is the wear being discussed in this topic what you are speaking of?

[754]

Yes.we should try to Mic a few and see the sizes.  I can't right now.

[Jerry Rxman Griffin aka MuthaF'er]

If you have an air impact gun the rotor will come off REAL easy 

As Frank says check out that roller surface/snout for unevenness. Did you order the starter clutch overhaul kit?

[scottly]

Hey Joe, I haven't tested the resurfaced hub; want to be the guinea pig??

[CBJoe]

If you have an air impact gun the rotor will come off REAL easy 

As Frank says check out that roller surface/snout for unevenness. Did you order the starter clutch overhaul kit?

Hey Jerry...I haven't ordered it yet.  I should have my rotor puller tomorrow so will check out the gear surface once I get it apart to see whats up.  I do indeed have an air impact...so should be easy.

Hey Joe, I haven't tested the resurfaced hub; want to be the guinea pig??

We'll see Scott   I guess I'd have nothing to loose trying it out if I find that the surface is worn.

[scottly]

Yeah, wait till you get it apart and inspect the parts. BTW the springs and the caps are usually good to reuse.

[754]

Should be able to pull rollers, springs and cups, without touching the staked screws.
 A Laverda guy showed me a neat trick. When you pull the gearvout of the rotor, keep gear on top.  Then cut a round cardboard disc or two and shove it in to hold the rollers... works well .

[CBJoe]

Should be able to pull rollers, springs and cups, without touching the staked screws.
 A Laverda guy showed me a neat trick. When you pull the gearvout of the rotor, keep gear on top.  Then cut a round cardboard disc or two and shove it in to hold the rollers... works well .

Yep...was able to pull the rollers/springs/cups without messing with the staked screws.  However the rollers themselves "look" good with no signs of wear

However, the Starter gears roller surface seems to have the slight ridging that Jerry and others have mentioned.  I can just feel the ripples when I rub my fingers.  May be time to source a better Starter Gear



I'm gonna message Bill to see if he's got any in his bat cave.

Another thought is Scottly's suggestion of machining the surface to smooth it out......has anyone actually done this? 

Joe

[Jerry Rxman Griffin aka MuthaF'er]

Scottly was playing with turning the surface slightly. Not sure where that has gone so far??

[CBJoe]

Scottly was playing with turning the surface slightly. Not sure where that has gone so far??

Bill is looking through his stash for a good one.

Scottly...if you are still up for it I may send you my bad starter gear and could be the Guinea pig to try turning the surface smooth.  Even if I install one in the meantime I could swap it out easily enough in the future.

I'm not planning on changing the Rollers or springs at the moment as they look really good.  I'll know soon enough the root cause.

Joe

[scottly]

Hey Joe, measure the OD of the hub near the seal end. Check it in several locations, feeling for the smallest spots. The one I cut measured 1.666" in the unworn area, and 1.664" at the smallest spot near the seal, but I had to turn the OD down to 1.660 to get a 100% clean-up, since the jaws of the calipers bridge the low spots. We don't know how far the diameter can be reduced before the ramps in the clutch hub run out of travel.
I can send you the .006 undersized gear I have; if I mail it on Tuesday, you should get it Thursday.
Scott

[CBJoe]

Hey Joe, measure the OD of the hub near the seal end. Check it in several locations, feeling for the smallest spots. The one I cut measured 1.666" in the unworn area, and 1.664" at the smallest spot near the seal, but I had to turn the OD down to 1.660 to get a 100% clean-up, since the jaws of the calipers bridge the low spots. We don't know how far the diameter can be reduced before the ramps in the clutch hub run out of travel.
I can send you the .006 undersized gear I have; if I mail it on Tuesday, you should get it Thursday.
Scott

Hi Scott...I'll shoot you a PM with addy and details.

Once I can find my Caliper I'll measure the one I have....If bill can find a good one then I can compare the both to the one you have to send.  I've got no problem testing the one out that you've turned down as it's easy enough to remove and install. 

Joe

 

[CBJoe]

Pulled the plugs.  Looks like 2/4 are running rich or carbon fouled.

Haven’t bike has done about 12 miles of in town riding.

Other than verifying float heights again any suggestions?



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Pulled the carbs to replace the floats and gaskets and rechecked the heights....Looks like I had 2 and 4 set too high.   Spec is 14mm +/- 1mm and they were set to about 12.5mm.  1 & 3 were spot on at 14mm.

Hope that did the trick...hope to have the starter issue resolved and the carbs back on in the next week or two.

[CBJoe]

Hey Joe, measure the OD of the hub near the seal end. Check it in several locations, feeling for the smallest spots. The one I cut measured 1.666" in the unworn area, and 1.664" at the smallest spot near the seal, but I had to turn the OD down to 1.660 to get a 100% clean-up, since the jaws of the calipers bridge the low spots. We don't know how far the diameter can be reduced before the ramps in the clutch hub run out of travel.
I can send you the .006 undersized gear I have; if I mail it on Tuesday, you should get it Thursday.
Scott

Hey Scott...I measured about the same on mine...high spots max around 1.666" and low around 1.664

[CBJoe]

Experimental Starter Clutch Gear installed from Scottly  .  This gear had the roller contact surface of the gear milled round again...I believe to 1.660"



The question now is if the slightly smaller diameter will still work reliably with the setup.  I purposely did not replace any of the rollers or springs so we know there are no other influences.  A backup gear is on the way from Bills batcave in case this doesn't pan out   

Unfortunately I cannot test it yet as I chose this time to clean up the handlebars controls.  Once I had replaced the bars with the CB400F Bars everything had a cobbled together feel.  So I just wanted to be done with it. 



I kept the Nissin Radial Master Cylinder...but am cleaning everything else up
- Domino Left and Right Bar Switches
- Magura 74.1 Sport Clutch Lever & Black Perch
- Domino Push/Pull Throttle and Grips
- Oberon Bar End Mirrors

A few parts are still on order, but hopefully will have them by the end of the week.  Then I'll be able to start everything back up.

Also ordered a Lucas Style Tail-light to relocate back to the rear fender along with a Slim 2 up seat from Texivana....should look like this



I'll keep the sweet Single Seat that came with the bike for normal riding, but I wanted to be able to take Rose to vintage event rides 

Once It's all back together I'm gonna get a dyno session scheduled up at the ducati dealer.

Cheers, Joe

[MCRider]

That's looking cool Joe!

When I had to repair my starter, it was just the caps, rollers, and springs. I used the old clutches. So I'll be interested in what you find.

Let me know when you go to Ducati and I'll tag along.

[CBJoe]

Will do Ron...Phaedrus gonna be ready any time soon? 

When I called Ducati about a month ago they commented about remembering your bike on the dyno   sticks in folks heads for sure

Joe




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[MCRider]

Will do Ron...Phaedrus gonna be ready any time soon? 

When I called Ducati about a month ago they commented about remembering your bike on the dyno   sticks in folks heads for sure

Joe

Yeah, we're making headway, slowly. For good or bad, it leaves an impression for sure! 



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[CBJoe]

Progress

I got the Domino Handlebar Switches all wired up and tested.  Got all functionality necessary including a Lap/Passing Button to flash the high beam 



Replaced the Dash and Gauge bulbs with LEDs...all seems to work well



I'm really pleased with the setup....once the wiring is all routed and buttoned up and the clutch installed I think it will look good.



Nice thing is that even though I don't have the carbs back on yet, I was able to test the starter out.  The starter clutch grabbed right away and all seems well....the real test will be time.

Joe

[scottly]

Nice thing is that even though I don't have the carbs back on yet, I was able to test the starter out.  The starter clutch grabbed right away and all seems well....the real test will be time.

Joe

Cool beans!

[Bankerdanny]

The bike looks great Joe. Hopefully we'll get a meetup set up down your way if not for this Fall then sometime next year and I'll be able to see it in person.

[CBJoe]

The bike looks great Joe. Hopefully we'll get a meetup set up down your way if not for this Fall then sometime next year and I'll be able to see it in person.

Hard to believe how fast time is moving...years gonna be over soon.



Pretty much finished the controls..all wired and working. Wasn’t happy with the Magura Clutch...it was angled too far away to be comfortable to grab the lever.



I just ordered an clutch assembly for a 2002 Ninja EX500 to use...it has an adjustable lever and will match the nissin brake lever as well.



Hopefully will have all done next weekend to actually ride.  Just trying to do it all just right and be done with it.

Joe



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