Sparky McSparky!

After a bit of fiddling with various stators and coils, I finally got some spark to the plug. Apparently I have about four different stator assemblies, two different ignition coils, and a random selection of harnesses. What I had in the bike was a mixture of I don't know what, and it wasn't working.

So I grabbed the stator off the original C110 engine and cleaned it up. It really didn't take much effort, as I just ran some emery through the points, lubed the little foam pad, and blew the crud out with some compressed air. After I installed it, I mounted the stock C110 coil and ran a few wires. I don't plan on running any lights on Salty, so I didn't use the stock harness or key assembly.

I found this wiring diagram online here:


I isolated the ignition circuit and just a ran a simple on/off toggle switch up to the headstock area. The switch is grounded, so that turning it "on" releases it from ground, and the magic sparks happen.

I was pretty excited to see the sparkplug spark. So much so, I called my pops right away, since he was over last night doing some troubleshooting with me.

C'

Front Number Plate

I've actually been fiddling with Salty a bit the past week, but don't have much to show for it. One of the items I did manage to complete was a front number plate. Which is pretty much a piece of plastic cut to shape. I'm not exactly sure why it took several days to put together this little item, but it did!



At least Salty has had some company, since Ratty has been hanging out next to him.

C'

Dirty Magneto is Dirty

I pulled the flywheel off a couple days ago, so I could get into the general flywheel/magneto area and do some cleaning. I took about half a pound of grunge off the inside of the flywheel, and began the dis-assembly and cleaning of the stator assembly.

The entire stator assembly comes off with a couple machine screws, and this is what I found:


Since I have a few extra engines, I grabbed a spare stator assembly that was in much better shape. I've already R&R'd the contact points, and will finish cleaning up the rest of the assembly tomorrow.

The "fresher" assembly:


C'

Flywheel Puller

I realized I had no way to pull a flywheel off the C100/105/110 engine, so instead of trying to fab up some puller, I hit the easy button and ordered one via the internets. After some quick searching, I came across a unit that apparently fits about 1 million other types of bikes. I picked it up from Heartland Products.



The big threaded boss threads into the flywheel, and the smaller section gets turned up against the end of the crankshaft. A couple gentle turns, and the flywheel popped right off. Be sure to keep track of the tiny woodruff key.


Chris H.

Salty, Front & Center

A few things got arranged tonight, so Salty has some room to work.

Long Time No Salty

It has been well over a year since I've blogged about Salty. Unfortunately, that also means I haven't touched the bike for a year either. It is sitting comfortably in the garage between the Bridgestone Sport 90 and the Hodaka ACE 90. Looking lonely.

Over the previous winter, I decided to build a new race motor for the Formula Vee. This was something new for me, so I took my time on it. I had the engine in the car running, about a week away from my first race date, when a rod bearing decided he wasn't happy. I pretty much pouted for a week, then pulled the engine out and tore it down. It was very obvious what had happened. I then spent the next couple months building up the engine again, this time with success.

I built an engine stand to run the engine on before putting it in the car. It ran great. Luckily, it also ran great in the car. I've made two race days with it, which also meant a bit of fine tuning to the cooling system (scoops and oil coolers) and a few other odds and ends. Before I knew it, it was winter again. I haven't touched the race car for several months, nor have I touched any bikes.

But that will change. My race club is lacking local events early in the year, so I've decided to jump back on Salty over the summer. I don't know if I'll actually get to Bonneville though. I would need to make that a primary objective, schedule vacation, set other projects aside etc. Initially, I just want to get it running and finish him.

I'm also going to finish a few other bikes. The Bridgestone needs a few small touches, I have a Yamaha YG-1T that needs some details too. Basically, I'm going to pull all the bikes out of the garage, walk around them and make a list. If it isn't raining this weekend, I may do that Saturday. I'll also organize the garage and make a real work center for Salty.

So keep posted, as I hope to have more stuff to blog about over the next few months.

Chris H.

More Tires, and Red Wheels

I've been busy working on my Formula Vee race car, and haven't given Salty much attention lately. Well, that changed this weekend. I received two more of my back-ordered tires (only one more rear tire remains) and set about getting them mounted up.

Installing a new front tire on the chrome front wheel rim, in the living room, while Susan watches Dancing with the Stars.



Last month, I had assembled a second set of wheels, using an older pair of wheel rims whose chrome was not in fantastic condition. I decided to paint the rims red, to match the tank and seat. I wasn't sure if I would like the end product on the bike, but figured what the heck!

Installing a rim band on the red wheel rim, before the front tire gets wedged on:


A note about installing tires. I don't have any fancy tire installation tools, so instead I use a pair of old screwdrivers that I've smoothed over on the end and edges, and a couple paint can opening thingies. You know those little guys that looks like a bottle opener, but have a small lip for getting paint can lids open. I also use some warm soapy water, and take my time. After a few tires, I've gotten pretty good at it.

And here is the half finished product, with a red wheel on the front:


I also had to make a new exhaust bracket, as the right side cover of the C100 3-speed engine has a little "bump-out" for the automatic clutch. Luckily I had more than enough room to move the exhaust out a tick to clear.

After I get the new engine built for the FV, I hope to get Salty up and running. Possibly over the long Christmas weekend.

C'

Test Engine Assembly and Mockup

I had a little time this afternoon (after a nice birthday lunch) to assemble the "test engine." This engine uses the 3-speed auto clutch from a C100, but with a higher compression C110 piston and the bigger port aluminum C110 cylinder head. The cylinder barrel and rocker box assembly are shared between the C100 and C110.


Right side of C100 Test Engine



Left side of C100 Test Engine



And of course I couldn't wait to get it mocked-up in the frame, to check the fit of the exhaust and intake manifold/carb setup. As it turns out, the "right" side engine case is slightly different between the C110 and C100. The C100 has an extra buldge on the clutch side because of the automatic clutch mechanism. This buldge hits the exhaust pipe I built. Just enough so that the exhaust won't bolt on the swingarm bracket. I have a couple options, the easiest being to extend the exhaust bracket, but I'm fearful that might make it look funny if it starts to "run down hill" as it exits the back of the bike. I'll need to spend some more time fiddling with it. Hhhmm.


Test engine installed, intake and exhaust mocked up on bike for fitment



Little Salty is really starting to look like a bike now



Another productive and fun day in the garage.

C'

Silver Side Covers

After a bit of photoshop work, I decided I liked having the side covers painted silver. So...I painted them silver yesterday. Exciting I know!

Silver side covers. The end.


After some work porting formula Vee cylinder heads, I'll get back on Salty. I should have one of my cylinder barrels back from the machinist, and will assemble the "test" engine.

C'

Front Fender Fun

All it takes is a little paint, and suddenly little Salty starts to look like a motorcycle. I prepped and painted the front fender over the weekend, and got it mounted up late last night. I just couldn't wait to see what it looked like.

It took a bit of fiddling to get the fender to fit just right, as it isn't the original C110 front fender. I'm not actually sure what it came off of, as it was just sitting in my spare parts bin. It looks the part and will keep salt spray off the engine when bombing along at 50mph.


Freshly painted front fender mounted on bike:



Close up of the front fender, still needing a good rubbing out and polishing:



Lastly, I test fit the side covers. The "left" side covers up the battery, while the "right" side covers up the air filter. I'm not yet decided on the final cover. I shot them black primer just to see how black would look, but I don't like it. Perhaps silver will work for them. hhmm.........


C'