Max, Snug .002 inch piston to bore clearance is to tight in my opinion. Especially with a cast iron cylinder. I prefer .0025 to .003 inch with the new Wiseco / Strictly Hodaka pistons. I don't know if the orientation of the piston pin clip is in the same position it was when assembled. But, for me, ...

If you don't mind me asking, how did you get the crank to look so good? In this case it really wasn't that difficult. All the gunk on the crank was soft and I would guess it is unburnt two stroke oil reside. A good soak in some old school carb cleaner removed the bulk of it. I soak a lot of engine ...

Looking a little better now. Drilled clutch cover for better oil flow.

Danny Cooke

Matt, I have used VHT matte clear wheel paint to coat flywheels. It is good for 250 degrees and offers some degree of corrosion protection. Thin coating is good especially the inside magnets. Since it is under the shift cover I am to worried about it resistance to carb cleaner etc. http://www.vhtpai...

Matt, The load applied to the transmission should not be that great using either tap or die. You only advance the tap or die about 1/4 to 3/4 turn, depending on material, reverse tap or die to break chip and repeat. Use cutting oil and low pressure air to remove chips. First gear should offer the mo...

Spudman,
Happy to hear you are back running. I also use Vintage Connections products and recommend them too.

Danny Cooke

Hey Matt, In the crank repair pictured I used a bolt that was one size smaller than original. You only have so much metal you can remove. Also, it is likely you may break through the bottom of the woodruff key cutout. You might be able to thread the existing stud for a different non metric thread si...

If you are going to relocate the condenser I would just remove it and get it out of the way. Just to be clear, the old condenser must be removed from the electrical circuit.

Danny Cooke

Spudman, You can repair the missing fiber ends on your coils assuming the windings are not damaged. The fiber board insulates and secures the windings on the core. I simply use Permatex Ultra Grey rtv sealant as a sort of potting compound to accomplish the same purpose as the fiber board. This seala...

20 wt fork oil, 6 ounce / 177.5cc per fork.

Danny Cooke

Roddy boy,
Yep forgot to mention the steering stop. You could copy the 03 pattern and I think I have seen some 94 stops welded up..but it was not pretty.

The 03 voltage regulator could be used, study the wiring diagrams and wire accordingly.

Danny Cooke

Roddy, You have a perfect opportunity for a front suspension up grade with the 03. Replace the entire front end on the 94 with the 03. Triple trees and all. I checked the parts list and some rear wheel components are the same. The sprocket carrier is different but you should be able to use the 94 on...

I have to assume that my 99 Road Toad is unique then, as I can remove my magneto cover without needing to take the shift cover/case off at all. Also, the magneto cover itself would cover both timing marks on the engine case if left in place. Are your bikes different? Spudman, Sorry, forgot there ar...

Danny-- I wonder if one could drill a hole in the shifter case over the timing mark to make it easier to do a quick timing check with a strobe light. Keep a rubber plug in the hole any other time. Bill, I had never thought of that before. I always try to seal the ignition cover best as possible to ...

Yep Road Toad is a chick magnet. If you really want the girls though, can't beat a old school ace 90....a real granny getter!!!!

Spudman, I use a timing light like you describe with no problems. Also have to use an external 12 volt power source. The mark on the flywheel and the mark to the right side of the engine case should align. My timing light has a timing advance measurement feature. If yours does also just make sure th...

Spudman, The turn signals on my 03 Wombat had the same slow flashing condition. At first thought I might need to replace the flasher. Made some basic checks before hand and flasher replacement was not required. I ended up taking both rear turn signals apart and found poor grounds. There is a ground ...

Interesting! I've seen several float pins worn like that . . . but have never had to use an extractor bit to remove a pilot jet. Ed Prior owner buggered up the pilot jet slot. Nothing left that I could get any turning force on. There was some pucker factor going on drilling and removing the pilot j...

Rebuilding and refinishing another engine for one of our forum members. Look at that. Clutch lever pin sticking about half way out. Great timing to pull this motor down. A few more minutes of running and this hardened pin could have gone through the gears and caused a lot of damage. DSCN2086.JPG No ...

Bike went to a new home in New Hampshire today.

Danny Cooke

Wonder exactly what has to be done to the Boyesen reed #613 to fit the stock Hodaka reed cage? Want to share that Danny? bchappy, The bottom reed is a little wider and needs to be trimmed. Also, center to center distance between the screw holes is sometimes a little short. I start by installing the...

Thanks. Good points. Again just curious what are the dual stage reeds made out of? Last I thought too much about reeds they were steel and the trick thing to do was replace them with plastic or maybe it was fiberglass - the idea being if the steel broke it lunched the engine and the others wouldn't...

Danny - why do you think the difference in reeds - carbon vs steel/plastic?? Dual Stage made a difference in 4 stroking??? Just curious. LBM It was just observation. Changed to the 2 stage reeds and mixture was not as rich at and just off idle....with no other changes. To be fair, some tuning was r...

Hi Danny Cooke! I have been watching this thread with great interest as I'm having an issue with my 100B+. Its been running poorly from about 1/8 throttle up. 'four stroking' I think .... I thought it was a tuning issue, but all adjustments have had no impact. I pulled the stator plate and there ap...

Spudman, Hodaka condenser capacitance spec is .25 to .27 mf plus or minus 10 %.....at least for the 125's. In researching this issue I found there are a lot of point ignition similarities between other brands of this time period. Every condenser I could find specs for were .25 mf for single cylinder...