The rebirth of Lazarus

[mickwinf]

Yes Graham I have had them before and been ok, it was the adjuster screw and spring didn't line up so had to bend the bracket to make it fit. Now not fitting in the shell very well so will leave it for another day. Decided to set ignition timing but now only sparking on 2/3, not sure if coil faulty or some other problem. Oh and no power from safety switch on handlebar. Definitely a bad day! On the other hand oil lamp going out when I spin engine over and did get a couple of pops from engine so there is some life there somewhere.

[Johnny4428]

You’re getting into the exciting stuff now Mick, considering what you started with. Once you sort out the niggles with the wiring you’ll have a runner!

[mickwinf]

This bike will be the death of me! Thought i would do something simple so fit the l/h engine cover with clutch mechanism and cable. Not going well, all seems ok but when i try to adjust the cable it seems to lock up and not return, the clutch slips when i use kickstart.If i then remove cover the clutch returns to normal. I am using new cable and clutch rod and have tried a couple of different spiral actuators so at a loss what to check next?

[Oddjob]

Try undoing the lock nut for the large slotted worm drive, turn this clockwise IIRC, make sure the inner worm drive doesn't move. It should be just tensioned by the return spring on it. I suspect the inner drive is too far out so you need to retract it by moving the outer drive.

Harder to write than it is to do.

[McCabe-Thiele (Ted)]

I've not reached that point yet Mick, I can see what Ken means though. I'm assuming you have shimmed the clutch basket beforehand.

[mickwinf]

Ken I have adjusted the outer slot as per manual, then taken up the cable slack with the cable adjuster. At first it seems OK but seems to lock in the clutch disengaged position even if I release play on the cable. Clutch basket was shimmed.

[Trigger]

Do you have the clutch cover off to see what is going on Mick. I have never come across this before 

[Oddjob]

Take the cover off Mick and take a picture of the insides, see if we can spot what the problem.

[Oddjob]

Did you fit the ball bearing inside the spiral drive? Been wracking my brains what this could be and with no ball bearing it could be the spiral drive hangs out of the housing when the clutch is pulled and it’s this which is jamming it open.

[mickwinf]

Well i have found the problm, it turned out to be the new cable of all things. The plastic liner was damaged and was not allowing the clutch mech to release and I didn't spot it as it was hidden under the rubber boot inside the cover. Will order a new one and keep plodding on. Thanks for the advice guys.oh what route should cable take is pic correct?

[McCabe-Thiele (Ted)]

Well i have found the problm, it turned out to be the new cable of all things. The plastic liner was damaged and was not allowing the clutch mech to release and I didn't spot it as it was hidden under the rubber boot inside the cover. Will order a new one and keep plodding on. Thanks for the advice guys.oh what route should cable take is pic correct?

When you say "hidden under the rubber boot inside the cover" I'm not sure I fully understand  what you are saying - is there some sort of boot between the end of the clutch cable and the inside of the cover?

[Trigger]

Well i have found the problm, it turned out to be the new cable of all things. The plastic liner was damaged and was not allowing the clutch mech to release and I didn't spot it as it was hidden under the rubber boot inside the cover. Will order a new one and keep plodding on. Thanks for the advice guys.oh what route should cable take is pic correct?

Sometimes it is just the simplest things 

[mickwinf]

Yes Graham it's always the simple things that drive you crazy and take ages! Ted, the clutch cable enters the sprocket cover and the open part of the inner cable is covered by a little rubber cover. So on the inside of the cover. The boot was covering the snag on the cable so I thought it was the clutch mech that was sticking.

[McCabe-Thiele (Ted)]

Makes sense I guess to keep water etc out.

[mickwinf]

I have sorted the motad exhaust so now moving on to the carbs. I have 2 sets including the originals and will see which ones are best to use. I could not resist squirring some carbon cleaner in the air intakes and turning it over, and for a couple of glorious seconds Lazarus breathed for the first time in 20 plus years!