After countless hours trying to get all the electrics to work I’ve given up. It’s now up for sale.
I bought a rebuild kit for the starter motor. Glad I did. The end cap bush was oval. I found the reason it stopped working. Someone had over tightened the terminal post and torn the main internal connector off at it rotated. Replaced bothe bushes, brushes, lubed bearing and soldered the internal conductor back to the terminal post. Took we 4 attempts to reassemble, adjusting end float, until it spun freely with a bench test. Re-installed it and the bike fired right up, instantly 😀
Got a few bits and bobs sorted this weekend.
Pretty chuffed with how this one turned out. I think it’s my new favourite 😻
I managed to fix the neutral light. Pulled the sender out and stuck a screwdriver driver in the hole. I managed to rotate the contact back to where it should be. I’m absolutely chuffed to nuts I don’t have to pull the engine out and split the cases again. YeeeeeHaaaa 😀
After pulling the engine, splitting the crankcases and spending several hours trying to understand how the kick-starter mechanism works, I figured it out. There’s a plate the controls engagement of the kick starter ratchet and it was bent. Bent it back and all is fixed.
Lapped the valves while I was in there, exhaust valve was bad, came up great though. Runs really nice now with good slow steady idle.
I have introduced another issue now though, the neutral light is on all the time. The engine will have to come out again as the sender is buried in the middle of the gearbox.
I put the engine back in the frame and started it up today.
Now I remember that the engine was making this grinding noise from the kickstarter previously. It still is.