Work continues. 3 fairly serious daze of labor so far.
Good thing Paul called it on this one their were some convoluted gotcha's RE the clutch.
Cable stiff, bound up but of course
Early style, nylon inner work gear was cracked, (they all crack).
I had bought a metal worm gear from an ebayer SEVEN YEARS ago. That got finally used on weathervane this year. Contacted Tim and hotdog he's still making them. Sent him my inner gear and arm, he will install the metal gear clocked correctly (this is a biggie) total $73
clutch push rod was installed backwards, small end towards clutch. (it had been installed backwards for a LONG time)
one of the cush springs on the back of the clutch had broken some time in the past and had been removed. the early baskets have some design differences later units were "improved" heavier cush springs better engagement of clutch plates I installed a later clutch complete.
this one was REALLY sneaky there were some small burrs inside the primary gear shaft that the push rod goes through. I took an appropriate size reamer and removed them. As a temporary measure Installed a later LH cover, with late style worm, drilled so the early lower screw/ferrule location works.
Clutch now functions! While I was in the LH cover removed stator, cleaned checked rotor, good at 5.3 ohms, changed outer brush for a new one.
Part way through the LH cover clean up.
Replaced front sprocket, reworked the shift shaft protector. At some point the chain had come off the rear sprocket and ended up on the wheel hub inside the sprocket, chain slopped around a bit did some damage but no case damage. Chain guard, front of rear fender will need a bit of massaging. Have new o-ring chain will go on. will replace rear sprocket also.
Removed valve covers, lubed top end with a squirt can.
need to set valves, cam chain. But it now has some compression.
Bores pistons look good.
Side filter was new but was missing gasket, as previously mentioned, I replaced the bent oil pump shaft and gear with a good later complete pump. It appears sump filter has never been checked, that's next on the list.
Lubing cables, front brake is now functional, cleaning and buffing somewhat randomly.
Ordered new exhaust, and front tire, tube, gas tank emblems, a reproduction seat, etc etc. Rear tire is good enough
for now.
Kick starter wasn't installed correctly, it is QUITE tricky on these early ones, later units have a snap ring that keeps the stack more or less together, the early ones don't. This has a needle thrust bearing at the cover. The gear size also changed, so I don't think a later unit will swap in. This type works, it's just fiddly getting and keeping everything aligned and in place when replacing the clutch cover.
Three carbs in the box of parts, one original carb had been left in a vinegar bucket too long and is toast. A replacement carb is from a later year and doesn't match. So need to sort, decide the carb situation. Air boxes are here, need paint, one new air filter, other is MIA.
Need to buy a battery. Wiring harness is pretty good only minor fixes needed.
Chrome, aluminum is in really good shape aside from some crash damage. A coating of dust grease acted as a preservative, the dry South Dakota storage really saved this bike!
Need to install fork seals and gotta find a correct set of fork gators, most don't have enough bellows to "look" right.
Still debating the paint situation, Bill has bucket, ears, side covers in more or less survivor condition. would like to find a "survivor green tank" but that's not easy, anyone holding?
May do some parts swapping with weathervane and end up with one survivor style, one more or less restored as new.
Already well past twice the purchase price in parts on order.
My wallet would be smoking!
