Magneto Cover Assembly

[tmehrens]

I just purchased a new magneto cover assembly. When putting it on do you align the shifter arm to the control shaft by temporarily putting on the foot change lever and going through the gears until the shifter arm aligns with the control shaft?

Thanks in Advance

[Dale]

I highly recommend a Shop Manual as it will cover this and nearly anything else that you need to know. Is your new cover greased? It won't be good for long if not properly greased prior to installation.

To install the cover, place the bike on a stand so that the rear wheel is free to move.
Rock the rear wheel back and forth as you pull the Control Shaft all the way out and then a tiny bit back in to locate neutral.
Remove the inspection cover from the magneto cover assembly.
On the cover, shift down until the Shifter Guide Arm is all the way out to the inspection cover opening. Then shift up 1/2 click to neutral.
Now the cover can be tilted and aligned so that the Shifter Sliding Pin fits into the Control Shaft and then into position to align the cover with the case.

Sometimes, on some models, foot pegs can be in the way and it helps to loosen them and move them back out of the way.

Hope this helps,
Dale

[tmehrens]

Dale,
I have a manual but it just showed me how to adjust it once it was on so this information is appreciated. I bought the magneto cover from Strictly Hodaka and was told it was greased and ready. To verify this would I just put my grease gun on the zerks and see if it will take any more grease? Also on the inside of the cover there is what looks like a blue rubber plug. On the one I took off there was only a hole. Do you know what the purpose of this is and with it gone might this have been the cause of my breakdown?
Thanks again,
Tim

[Dale]

Tim,
Not sure what the plug is about. Can you post a picture? There is typically not a plug inside the cover...

The key to a good working and long lasting shift cover is to keep it clean and greased. The grease zerts alone are not enough. Use a good quality, waterproof grease such as Bel-Ray. Grease every metal to metal contact point inside the cover including the sliding pin and the control shaft that it rides in. Some folks literally pack the entire shift cover from the Shift Arm down. Like the lower third of the cover. I do not completely pack mine, but I am pretty liberal with the grease.

Then after riding in dirty or wet conditions, remember to clean and re-grease the shift cover. It will be worth it...
Dale

[BrianZ]

Does the plug cover the hole where the control rod would protrude into the shifter case when it is installed? I'm guessing this plug is to prevent dirt from getting inside the shifter mechanism (and grease/oil getting out) and is to be removed prior to installation.

Brian

[admin]

Hi Tim,
To mate the shift guide arm rectangular sliding pin to the notch at the end of the control shaft you will need to remove the little inspection cover from the shifter assembly first. Depending on where the the sliding pin is located based on the shifter guide arm assembly is you may need to pull the control shaft out or push it in the allow the guide arm with pin to mate to the control shaft. To move the control shaft in or out it would most likely need for you to slightly rotate the rear wheel. To move the sliding pin in or out you will need to use the shift lever to "shift" up or down.

As for the blue plug you mentioned. When George rebuilds the shifter assemblies he uses silicone to fill the cavity for the shift guide arm pin. This cavity runs through into the round part of the shifter assembly that covers the magneto. This cavity is found on all shifter assemblies that say "ACE 100". George fills that cavity hole just to help keep dirt or anything from getting into that hole. It just keeps it clean.

Thanks
Paul

[tmehrens]

Thank You all for your advice I really appreciate it. This bike is the same model and year as my first bike that I got for 8th grade graduation. Thanks for helping me relive those carefree days!