I hate to ask, and I may be in left field, but did you do a pressure test? After that, when you say too rich but plug "looks" right I'm a little lost. If you've gotten 60 out of her I'd say you are in Fine Tuning Zone. Here, some Half Size pilot jet changes might bring you closer. There is...

Thanks Matt, never would have found it.

But I'd like more.

What's the gasket sealant that was or can be used?

Anybody know?

The later Strictly Hodaka after market ones were re-fitted with little tiny O-Rings in those grooves.

I've done it, but it's a real time killer. I'd say this: If they are the originals you might have success IF you have various FINE grades of lapping compounds on hand. I'd say 400 grit & 600 grit. AND you drive the little cone thing at maybe 50 to 100 rpm with maybe a low power portable drill. H...

93 Rat Roller vs Bronze Bushing.jpg This may or may not help, but The Book says Hodaka reverted to the bushing for the Rat. Maybe the roller caused some trouble for them. One other idea: the Ace Case MAY be able to be bored to accept the roller bearing. A tricky job, but if the right target diamete...

ddvorak can help with the condenser relocation information. Soldering in replacements to the stator is a pain & I'd give it up if I were you. ddvorak can also connect you to a procedure to verify your coil, plug wire & plug cap using a couple D cell batteries & some wires. I've used this...

https://youtu.be/nV8prGHTlIM

The gentleman in this video has been reported to recondition stator assemblies.

His phone & email are at the end of the video.

This may be an option for you.

Hodaka parts does show the lines available for order at around $8 each.

This is low pressure stuff.

Tygon tube on the inlet side would be fine.

Any automotive vacuum line that fits should be ok for inlet & outlet.

Just my two cents worth.

Socalhodaka's suggestion is best. You're not going to get a better value than joining & getting access to the Resonator articles.

That, or get the Hodaka Workshop Manual.

Best bet, do both. If you're opening up one of these things you're going to want the whole package of info.

You'd be playing it safe if you did as suggested: contact Hodaka Parts.com. it's not cheap, but most likely it'll be right. They have the parts inventory. If you already have your Piston kit and they think it's suitable they'll tell you and get the work done with what you send them. If what you have...

I don't know the answer, but my old Ace Kick Gear seems machinable with carbide. I'd have thought it might be too hard to turn, but the Stock Ace one isn't. Looks like you can Mill it off with carbide endmill. Maybe high speed steel, not sure. Only other thing I know is the racing transmission fit m...

I use the Denso Iridium. I guess I got sold on their claim that the smallest diameter electrode yields the best spark. But I'm a street rider, not a racer. I've visited the Champion plant in Ohio where they made the ceramic insulators. An awful lotta work goes into them. They seemed very focused on ...

Excellent information from Mike perrett. The rectifier keeps alternating current from reaching the battery. It only lets in the Direct Current pulses. If AC current gets to the battery it'll eventually cause failure. Maybe fast. I've wondered about a modern replacement for the stock selenium rectifi...

Thanks for the replies.

I left the expander in.

Seems to run fine.

Sorry, I meant number 46 on the exploded diagram, not 16

922715.jpg I've just installed a piston & ring set that includes the Expander Ring, Number 16 on the exploded diagram shown in this post. I've never installed a piston set with one of these Expander Rings before. It's quite a trick to get the Expander Ring and the Piston Ring aligned with the a...

I'm late on this one, but to remove #19, part 902020 Shifter Pin from Magneto Cover..... Heating the Magneto Cover near the pin location will help both on removal and installation. I use a heat gun & wear gloves. I expect careful use of a bernzomatic type torch will do as well. As I recall I alw...

I copied this diagram from the Hodaka_parts.com website.

Dozerash: if you find this diagram helpful you might like to check the website noted above and click the Search By Schematics button.

This may be of some help.

As an aside, the Ace Shop Manual mentions flushing the transmission/clutch cavity with kerosene.

Might be worth considering. Could help de gum what's gummed up.

JPark

If you decide to proceed as you've outlined please take pictures as you progress & post them.

Oops, that's right. The pin that contacts the throw out bearing is about 5 mm diameter & 10 mm long. It can easily slip out. It's small & you may have missed it. Put it in place with grease as mentioned. Then put the cover back on. Without this piece in place you'll get no action at all.

Your comment about no resistance on the clutch activating arm is a serious concern. Something is wrong here. The clutch pack has several springs & they push pretty darn hard. IF the lever on the clutch cover is functioning and the throw out bearing looks pretty good I'd guess it's time to pull &...

I find that I can't hear much of anything over the rat pipe. I don't think I've ever heard induction roar with the ACE, but I swapped to reed intake over a decade ago. And had the reed manifold modified for two pedals & modern reed material. Took a quick search on the net. Seems helical & sp...

Swapping out to the straight cut primaries on my Ace 100B gave me audible gear whine that I didn't have before. But I solved that annoiance when I swapped out the Ace "flamethrower" pipe with a Rat pipe and DH silencer. Quieted them right down. I can't tell you anything about noticeable po...

Well, are there some known temperature ranges, in degrees F or C that are known to be damaging? I'd guess if it's hot enough to seize that'd be one. Iron cylinder, aluminum Piston..... Differences in thermal expansion resulting in excess friction. Or, too hot & lubricant fails to lubricate &...

I too have used a condenser from an auto parts store & mounted it at the coil. I've got the Ace. Been running it like that for years. Left the under the flywheel condenser where it was. My guess, and that's all it is..., if the existing condenser isn't shorted or doesn't short at running tempera...