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Author Topic: Removing Electric Start  (Read 979 times)

Guaire

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Re: Removing Electric Start
« Reply #15 on: October 05, 2013, 12:03:43 PM »
That worked!
Any progress I've made comes from the help here: motomataya, ERC, RGT and Arizoni.
   The primary is off. The gear that drives the starter is out. Visible are three shims. The paired driven and drive gears are visible. How do those come out? It acts like one part. I checked the parts fiche at Hitchcock's. It looks like two pressed gears. There has to be enough room to spread them apart and remove them!
  Anyone remember how to split these two gears?

ERC

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Re: Removing Electric Start
« Reply #16 on: October 05, 2013, 01:25:15 PM »
That gear should come right out with the small cover on the back removed.  ERC
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.

Guaire

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Re: Removing Electric Start
« Reply #17 on: October 05, 2013, 02:11:48 PM »
The cover is gone, but these two gears on the same shaft have nowhere to go. If I could pull the shaft, it might come out, but I can't. If I could find the right puller, I could push the shaft down. I don't know if that would accomplish anything.
  Here's pics of both sides of the inner primary case and the gears.

Guaire

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Re: Removing Electric Start
« Reply #18 on: October 05, 2013, 02:25:23 PM »
Parts 9, 12 and 13 are visible in the photos. Here's a fiche from Hitchcock's.


Arizoni

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Re: Removing Electric Start
« Reply #19 on: October 05, 2013, 02:35:03 PM »
Does the hole in the shaft in that large gear have a thread in it?  If it does, it may be intended for a puller screw that would allow a puller to bridge the shaft and push against the face of the gear.
If the shaft (#13 in the Hitchcock picture) was pulled out of the gear the gear would easily slide out of the housing.
Jim
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1999 Miata 10th Anniversary

ace.cafe

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Re: Removing Electric Start
« Reply #20 on: October 05, 2013, 02:45:37 PM »
That whole gear cluster and the center shaft behind the hump just pulls out after you have the cover plate off the back. You can usually just pull on the shaft, and it all comes out.
If it's stuck, there's nothing holding it there but friction. Get a good set of vise grips and put a piece of leather on the shaft, and lock the pliers on and pull the shaft out and the gears will come out with it as a unit.
Home of the ACE Fireball 535 Bullet,  and the Joe Mondello Signature cylinder head for the Bullet.

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Guaire

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Re: Removing Electric Start
« Reply #21 on: October 05, 2013, 04:35:09 PM »
Way Cool! Gotta button up today. I'm doing that tomorrow.
Thanks, everyone.... I'll weigh the 'removed' parts when I'm done.
Bill

neil

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Re: Removing Electric Start
« Reply #22 on: October 15, 2013, 05:04:23 PM »
Hi Bill:
You'll have about half of the weight reduction with what you have accomplished so far. The rest is in replacing the "lump" inner primary with kick only inner primary and by tossing the heavy oem battery for a light weight jell battery. That will get you the 20 to 25 lb reduction. Also center of gravity moves back and lower in the frame to improve handling.
No more sprag worries and improved handling, ya gotta love it.

Neil and Buzzy the Bullet.

n1acguy

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Re: Removing Electric Start
« Reply #23 on: October 15, 2013, 10:11:45 PM »
Yep, seems like I lost 20- 25 lbs when I did mine.
If you ride it regularly the smallest battery you can find is enough.
These little ones are probably even good enough for an occasional ride if you put a tender on it.
My 2˘ YMMV

neil

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Re: Removing Electric Start
« Reply #24 on: October 16, 2013, 09:41:17 AM »
Second to that ! ! !
My battery is small enough to place in one of the tool boxes out of sight. Gives the bike that see through look mentioned in the E.G. catalogue. I love it.

Neil

cyrusb

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Re: Removing Electric Start
« Reply #25 on: October 16, 2013, 12:58:18 PM »
Like this?
« Last Edit: October 17, 2013, 10:35:07 AM by cyrusb »

Chuck D

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Re: Removing Electric Start
« Reply #26 on: October 16, 2013, 01:48:47 PM »
2006 Bullet Sixty-5 w/ Ace "Fireball 535" Kit (#10)
(Head  back at Mondello's for the "Raised Port" and ratio rocker upgrade. Stay tuned!)

'76 Honda CB550Four K


"What's so funny 'bout peace, love, and understandin'?"

Guaire

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Re: Removing Electric Start
« Reply #27 on: October 16, 2013, 02:46:03 PM »
Great pic of the open look. I'll go with either a Ballistic, lithium iron or a gel on the battery. It was set up with a massive Sears Diehard because of the electric start.
  I just got back from my trip to Alabama. I'm ready to work on it tomorrow. I still have to remove the starter cable, solenoid and a bit of other wiring.
  My welding buddy removed the gears by cutting them like a pie. The shaft never gave up the gears. He tossed the gears when he was done.
  Here's a paste in from a link out of the CD manual from nfield gear.
"Remove the starter, the primary case outer half, the alternator, the engine sprocket, the clutch and transmission sprocket and the primary case inner half. This entire process is documented and illustrated in section 5 of the Bullet Electra manual and section 3 of the Bullet Service manual which are both available from CMW and everything you need to know will also be found in Pete Snidel’s manual along with tips not found in the other two manuals.
Remove the wire that runs from the starter back to the solenoid in the left hand tool box.
Remove the solenoid.
There will be two wires going to each battery post. One will be heavy gauge and the other a much smaller gauge. Remove the heavy gauge wires as they were only needed to carry the high amperage drawn by the starter.
Drill and tap the bolt holes for the 5sp KS only inner chain case.
Have the starter gear machined off of the engine sprocket.
Attach the primary case inner half.
Replace the clutch and alternator.
Replace the primary case outer half."

cyrusb

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Re: Removing Electric Start
« Reply #28 on: October 17, 2013, 10:53:29 AM »
Show off. ;)
Sorry Chuck, I can't help it! Since these pics it has received a right side shifter and a much needed 19t countershaft sprocket.

baird4444

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Re: Removing Electric Start
« Reply #29 on: October 17, 2013, 11:45:27 AM »
Hey Bro-
    great job on the open look, Love it!! That hump was never an issue
    with me but I do love the open look. Have you considered moving the coil
    to one of the side boxes? that would be the final touch. May as well make
    it a Bosch Blue while you are at it!!
       yea, looks great -  Mike
"You can't drink all day if you don't start in the morning!! "
        -Cody Baird
'My dear you are ugly,
 but tomorrow I shall be sober and you will still be ugly'
 - Winston Churchill