Basket Cases

[Jools]

Always good to see all sorts. Though somehow I prefer looking at the 'before' bikes... they all look different, whereas restored ones all look the same.
Or maybe it's the tempting look of a potential restoration project.

[PA]

Do we have after shots of theses Honda ?

They are the after pictures.

[David Lahey]

Do we have after shots of theses Honda ?

I expect we get a 4 stroke 2 stroke Greg Harding Franken trials bike

[Kurt]

I've been wondering why Gregs name has turned gold.

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[Rod]

Do we have after shots of theses Honda ?

They are the after pictures.

Piss Funny, I'm still chuckling.....

[David Lahey]

After seeing Kurt's posting all I could see was Joe Henderson riding his Kenbroken in a trial wearing the shiny gold Elvis Presley costume.

This one looks a lot more realistic

[David Lahey]

I'd been having problems with the motor stopping in tight downhill turns with the clutch pulled in on my 52 years old model 49 so started with checking how much clutch pushrod travel I was getting. The mechanism is a multi-start worm or "bendix" that was phased out on in about 1969 but was continued to be used by other manufacturers (Suzuki, Yamaha etc) for a while longer until the Japanese caught up with design advances (that bit was especially for Graham Weiss).
There was a bit of play in the bendix on the bike so I thought I'd take it apart and have a good look at it.
Here's what a bendix looks like. The one in the photo is actually a less-worn bendix than the one that came out and it was nice and clean so got used for the photo.

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.
The clutch cable goes on an arm that twists the male part of the bendix and it sits in the engine cover like this.

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The male part of the bendix has an adjustment screw through the middle to set the free-play for the pushrod and the end of the screw is what pushes against the clutch pushrod. The clutch pushrod sticks out the end of the gearbox shaft that carries the front sprocket and has the clutch on the other end.

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The clutch pushrod has a rounded end to create point contact with the normally-flat end of the screw, to minimise friction while the clutch is pulled in.
This bike though has seen enough hours with the clutch pulled in that the end of the adjusting screw has worn, eventually becoming a hollow depression that perfectly fits onto the dome on the end of the pushrod. I'm not sure you can see in the photos but the end of the screw has turned blue from heat and has belled out. I suspect that the friction there might be what has been causing the motor to slow down and stop when the clutch is pulled in and the bike comes to rest. So I'm going to make the end of the screw flat again and see if the problem is still there.

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[Jools]

Yes that's why later they fitted those lovely little rotary roller thrust bearings, (I'm sure there's a technical name for them... anyway...)

[Bully fanatic]

That is interesting David. I haven`t had much to do with the early Bultaco engines. I have worked on a few but not to that much detail as yet. Don`t forget they had a 125 roadracer which came out in 1966 with water cooling, 6 speed gearbox and a CDI ignition so they were not behind the times bu any means.

[Greg Harding]

Hi Everyone,
David, it looks like there is 3 possibilities for fitting that bendix, it might pay to try all 3 as sometimes the machining is a little out. One position might have less drag/friction than the other 2?

That is a cosiderable challenge you have set there Kurt with your cryptic golden post! For the record, just one head gives me enough problems!

Do we have after shots of theses Honda ?

They are the after pictures.

Eagle, do you mean you want photos from after I fix them? What I was asking is what do you get when you add them together? Here is some more photos of the 200 because I know you are a TLR man:

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Just for the record, I am with you Rod:
GOLDMEMBER