62 FL Chop Rebuild 10
My grandson Elijah paid me a visit at my shop,
and naturally, he wants to take the "PileDriver II" home with him....
Got the insides out of the rear brake MC....
It looks like an 11/16" bore, need some parts to rebuild it....
Found the parts I need online....
Found the old wiring diagram...
I never did wire in that capacitor, but have one now and will install it,
It should make the lights come on faster when I hit the switch....
Uh oh, ran into a problem, I didn't try fitting the generator onto the motor in the frame
back when I was first fitting everything together for the first time....
Now I find that the generator hits the left side down tube and does not fit in
this Denver's Frame I had custom built for me...
The scroll cage on the fan hits the left down tube...
The generator won't seat correctly against the case....
I think the problem is that Denver's set up this frame for the smaller 3 brush generator,
and did not allow enough room for the larger air cooled 2 brush generator that
the police special motorcycles came with. This bike was originally a
Honolulu PD motorcycle, and came with this high output generator.
Have not decided how to handle this yet...
Started setting up the clutch, not sure how to lube these roller bearings for the clutch basket...
Put a little grease, a fibrous looking wheel bearing grease, on these bearings....
And started putting these together...
The spring pack is pre-compressed in the pressure plate assembly....
Not sure what these spring loaded steel balls do,
most likely an anti-rattle feature....
Four steel plates and five friction plates all loaded in....
Ready to bolt it down....
Had to climb on top of this to compress the springs with my weight to get these nuts started...
Then installed this center adjustment nut with washers to lock the spring pack down
so the three outer nuts can be removed, while keeping the springs compressed....
This frees up the spring pack so it can be removed separately for
installation of the clutch setup on the tranny...
Everything in place, adjusted the belt tension...
1/2", should be around 1" or so, need to loosen some more...
It's a new belt, so as it quickly wears in, I'll need to watch it closely and keep readjusting...
These belts will run just fine with a fairly loose setting, and the bearings at both the
motor and the transmission will thank you !!
Got a problem here, the belt is too close to the frame....
I'll have to put some spacers under the tranny plate to raise it a little...
1/8" will probably be enough....
Always something....
Used a 3/4" hole saw on some 1/8" flat stock and cut some spacers, then drilled them out to 3/8" for the bolts,and
put some fresh black paint on 'em....
Pulled the fan shroud off of the generator, it fits that way, so looking at mods for the generator shroud...
Found some good grease for the clutch hub bearings...
It's been around awhile in my shop....
Fibrous and sticky, should work well....
Painted and mounted my rear foot pegs,
I don't use folding foot pegs, these are pipe, welded plate on the ends,
act as crash guards if I go down, and in the distant past, did just that, kept most of the bike unscratched....
Those mounting tabs are solid !!
Hung the front one, same things, act as crash guards....
More Later
