The Hodaka Club Forum

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.

Rick. What did you use for the seat repair that's already threaded? Victor

Victor,

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.

https://www.amazon.com/Astro-Pneumatic- ... D272HFTD5J

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.

What do we think?

I think the problem was a thrown chain not a broken chain that generally does the damage. --Clarence

Rick. Do you want the set of Ace 100 cases I have? You can have them for shipping if you want them.

I can post a few pics if you want to see them. Victor

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...

Bill2001 wrote:?..... The protector could be made of 1/8" steel 3/4" wide and have stout brackets to M10 bolt holes in the case.....

Where on the engine case would you place an M10 bolt?

Someone posted this a while back. Called it a case saver.

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.

Thanks!

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.

You could conceivably put both ideas on the same piece, case saver and replacement post. Bolt on and cure 2 problems.

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