Model 97 - Finally getting started

[taber hodaka]

What you can see of your piston it looks good, how loose is it in the cylinder? ------Clarence

[gearyoliver]

Clarence, it's not too bad. It wasn't stuck in the barrel and felt pretty tight. Shouldn't have to over bore much.

[taber hodaka]

Check tolerance you could be within spec. If you haven't cleaned the top of the piston, it looks new almost. ---------------Clarence

[Bullfrog]

Side of the piston is scored, but I've re-run worse. I'm with Clarence, check clearances - it might be ok without boring.
Ed

[MTrat]

What end gap is correct on that dykes ring?

[ossa95d]

The general rule of thumb for ring end gap is .004" per inch of bore diameter. On a 50mm bore that would be .008".

[gearyoliver]

After cleaning.

I will get some feeler gauges and check. Have some somewhere, easier to buy new ones.

[gearyoliver]

Haven't got to checking clearances yet. However after searching, reading and thinking, I've seen a few posts on different gear sets. Given that I have a basket case model 95. Should I consider using those gears if they are good? And or should I consider building the entire bottom end from the model 95? The hoped for end use for the bike will be 99% making an old fat guy feel young. 1% letting my 150# little brother thrash it at Hodaka Days.
Decisions decisions

[Jack Elliott]

Hi Geary
I love my super combat and pretty much use it as you want to(the old guy feeling young part) from my limited experience and reading I do feel they are pretty much pushing the limits of the 95 gear set. I think new bearings seals and rod kit with the improved 97 hardened gears and cushioned primary will make it much harder for the little brother to blow it up...

[viclioce]

.

[viclioce]

Gearyoliver. I just checked my gears. All of them are 28 tooth 2nd Gears & 25 tooth 3rd gears. Sorry. I guess that’s the diff between an enduro tranny and a close ratio MX tranny.

I hope there’s someone else out there who can help you. Victor

[olddogs]

You can put the entire 95 internals inside the 97 cases, but be sure you include the kick gear.. The 97 uses a bigger OD mag side crank bearing and a few different style bearing/bushings for transmission support, but none of those need to be changed if good. The bigger mag bearing has the same inside diameter so cranks interchange. I have raced and trail ridden both the 97 and 95, and find the close ratio 97 gearing to be quite busy. A lot more shifting, a lot more often. Great for the young and foolish, tiring for the old and experienced. Keeping the K cases will keep the motor and F frame numbers original, increasing the value if you ever sell it.

[gearyoliver]

Jack, it wouldn't matter if I put gears from a D9 Caterpillar. My brother could break it.

Victor, the offer was even more appreciated than whether or not you even had one. Thank you!

olddogs, thanks for the info. I'm thinking I'm gonna pull the 95 the rest of the way apart and see what I've got. If it's good I might use the trans, at least for now. And while I do want to keep the cases original if possible I am never selling it. It took me over 40 years to get one.

[gearyoliver]

Putting the engine aside for now. Have a master welder repairing the right center case. I have degreased, scrubbed with dawn, steam cleaned and pressure washed. I can not get the cases and covers clean. Finding someone to blast them is the next step I guess.

So I thought I would tear down a little more.
Frame looks like rust is mostly surface. Going to pick up some paint stripper and get started.

[gearyoliver]

Just picked up a donor 03. Hoping to use the forks tank and seat for the Super. Engine to be used to resurrect an 03 I got a long time ago from the original owner with a missing shifter and stuck motor. Hopefully some visible progress in the next few weeks.

[viclioce]

I’ve acquired an 03 motor as well. It’s been sitting in the shipping box in my garage for over a year now. When I’m done with the Green Toad, I have to do a tranny kick start bearing retainer repair on the Ace. Then, I will finally be ready to start on that 03 motor. It will go in this bike! Then I’ll use the 94/95 motor in it in another frame! Victor

[gearyoliver]

I have a donor 1977 CR125. I was wondering if I could swap out the forks and how much work it would be. I saw one at HD so I figured I should look into it. So it turns out there is no fabrication other than fork stops. I also mocked up the CR swingarm, shocks, and rear wheel. If I were to go this route there will be some mods required. Then I stuffed in the CR airbox. Interesting, might have to look at that closer down the road.

[gearyoliver]

I already posted a picture of my 97 repaired case. I finally got around to dissassembling the 95. You can see where the case is broken on this one and since the trans looks almost new I assume this was why it was junked. So for now I am going to get this repaired and put the bottom back together with new bearings seals etc. Now I have to decide which top end to use. 95, 97 or 03. I'm leaning towards the 03. Hopefully more progress soon!

[gearyoliver]

Except for one itty bitty broken tooth.
Third gear on the main shaft. Grrrrr.
If.im looking at the schematics correctly the same main shaft is in the 95 and the 02. Part number 99450. If so I have a spare 02 engine. Maybe I'll get lucky.

[Bullfrog]

Better look again, 95 series mainshafts and 02 series mainshafts are NOT interchangeable.
Ed

[gearyoliver]

I thought they wouldn't be the same. A person shouldn't copy and paste late at night.
95 mainshaft 944500
02 mainshaft 994500
I think I have a lead the correct one.
Thanks Ed.

[gearyoliver]

Well, I did have a lead on a 94450 shaft. But that's not what I needed either. I posted this on FB last night. Got some good information. Dealer close ratio gear set which explains why I couldn't find it in any parts list.

[gearyoliver]

Hooray! Terry Larson has a new 2-3 gear with my name on it! So now I'm thinking about putting the 95 engine back together with an 03 barrel and running it in the SC for now.
Terry is working hard on inventory and has found some treasures recently. It's a good time to be fooling around with Hodakas!

[gearyoliver]

Edit; Oops Kolene, not Noleen. Ughhhh.

I had to put this on hold while I collected parts which has been quite a fun experience. Here is where I am so far.
I had the cases welded up but have decided to find a good pair. Greg at Cal Hodaka is refurbishing a pair for me.
Crank rebuilt - Ron Liddle
97a transmission - Danny Cooke and Greg and Diane Watkins
Cushioned primary - Greg and Diane Watkins
Rebuild kit and Kolene Clutch plates - Hodaka-Parts

[gearyoliver]

So now I have to make a decision about the top end. I can do the basic port matching and cleanup but that is about as much as I am comfortable with. In the interest of rideability vs. all out power I am looking for opinions about how far to take this project. I would like to figure out a step by step approach. I would like to use my SC barrel although have an 03 if I had to use it. What do you think?