Besides the Dirt Squirt project with my Grandson, I have another Hodaka in the wings. An Ace 100B. It has taken some twists and turns during the last few weeks. But I am confident it will be a nice runner when done. It is not a total restore, just a re-assembly. Only painting if it component really needs it. I have 95% of the parts I need. The motor is the thing that will be the most challenging if I want to keep the cost down.
The motor case on the Ace 100 is damaged and it looks like I will be using the motor from the 96 DS project.
I recently acquired a 98 Super Rat motor. This might become the DS motor. The parts that are interchangeable between the 3 motors needs further research. Here are some photos of the progress and present state. I used several parts from my old Ace 100B+ that is now my Spyder trials bike. That's 2 bikes that have benefited from my original Ace I bought new in 1973. This bike and my WomAce 125.
The clutch seems ok.
Broken boss.
The seat pan needed repair
Here is what it looks like todaay
Rick Mott
In order to be old and wise, you must survive young and stupid!
The original bracket was already threaded M8 1.25. The one I made I used a rivnut, 5/16-18 because at the time I didn't have metric rivnuts. I do now. See link for the set up I bought from Amazon.
On the broken boss at the shifter:
I've wondered if one could make a "chain deflector" that curves around the sprocket and protects that breakable boss from chain contact. The protector could be made of 1/8" steel 3/4" wide and have stout brackets to M10 bolt holes in the case. It should be strong enough to deal with a broken chain and easy to fabricate. I thought of this last time i had the shifter cover off for repairs. I've certainly read enough reports of broken shifter bosses to make it worthwhile.
taber hodaka wrote:I think the problem was a thrown chain not a broken chain that generally does the damage. --Clarence
So by "thrown chain" you mean one that has derailed or jumped off of the front sprocket. That is a whole different ballgame than a broken chain. Sounds brutal...
Yes!! That is exactly what I envisioned. I was thinking a bit more clearance between the sprocket and the rail, but I was looking at a different failure mode. I didn't find much here searching this forum on "case saver", I'll need to dig more.
The case saver is a very similar design as the one for Sachs motors which also have case damage issues from chains jumping the sprocket. One of the Penton guys designed and fabricated a case saver that bolts under the sprocket cover and doesn't interfere with the cover or sprocket. On the Hodaka there has to be a hole for the shifter shaft, on the Sachs it has to have a hole for the speedo drive, so very similar in design parameters.
Rick. I fixed my seat today! The idea came to me and it was so simple I don't know why I didn't think of it before! It's posted in my 4th Hodaka 2nd Road Toad thread! Victor
Victor