Project Racer - Monday 27.02.2012/XNUMX/XNUMX

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Unfortunately, the last days before the custom show in Ried were a bit hectic, so there was no time to maintain the blog.

Nevertheless, we do not want to withhold the last steps and pictures from you.

The motor is temporarily hooked into the frame to test whether everything fits and there is no pinching.

Of course, not everything fits the first time you try it on. Why also?

No seriously. The frame must be adapted to the Falc intake manifold because the shape of this must be shaped in such a way that the carburetor does not hit the frame in any driving situation.

Here it is enough to remove a few mm so that the Falc socket fits.

The 38 Airstriker is being converted to a cable choke.

The CDI of the ignition also needs a place. The retaining plate is intended for conversion to V50 and Primavera engines, so a second hole must be supported and countersunk.

In the SmallframeThere's a real shortage of space for the CDI at this point, which is why the retaining plate, which is vibration-dampened in Piaggio rubbers, has a special perforation so that nothing is offensive even when it is fully compressed.

Here is the "wedding picture"

Now the adjustment of the steering tube still follows.
As a result of the conversion, the top of the steering tube must be shortened and the undercut for the clamping screw of the handlebar must be moved.

So the old undercut must first be welded shut and then a new one must be filed in the correct position.

The handlebar can be mounted.
A PK-XL rocker arm is used with our engine. In connection with a V50 and ET3 standard rocker switch in the handlebar, however, this results in too long a shift travel.

That's why we use a PK-XL pulley to keep the shift travel short and crisp.

And here, too, the devil lurks in the details:

Compared to a V50 / ET3 rocker switch, the PK pulley is oriented a little further towards the end of the handle. As a result, the shift cables would now run at an angle between the cable stop in the handlebar and the pulley, which increases the wear on the cables and leads to poor switching behavior.

So it is necessary to lengthen the switching tube by a few mm so that the pulley and cable stop are in alignment again.

The connection point for the planned extension of the switching tube is deliberately set as far inwards as possible, otherwise, if one only had a steel ring a few mm long, there could be problems with welding.

With the extended shift tube, the roller and stop are again in alignment and the shift cables are now straight.

On the gas pipe side, we also have to come up with something.

A conventional quick throttle grip is out of the question for our classic racer for optical reasons.
It would also be possible to use a pulley. The size would be enough to fully open the 38 Keihin.

A herd of 29 horses, however, needs to be led with a gentle hand and so the linear opening path of an exactly round roller is not possible.

A progressive gas roller, on the other hand, has the advantage that the carburetor is opened slowly at first and faster as the slide stroke increases. This effect clearly takes the nervous behavior out of the resonance range.

Pay attention to the track for the throttle cable in the picture below. If you look closely you will recognize the eccentric course ...

Since we manufacture the throttle pulley ourselves, the dimensions are determined accordingly so that the throttle cable runs straight from the cable stop to the pulley.

The orientations of the holes for the clamp and the screw nipple are then fixed in the handlebar.

A screw simply serves as a stop for the roller. Adhesives are used to prevent it from coming loose.

Finally comes the tank, here with a Fastflow fuel tap with reserve indicator.

It takes a little getting used to, however, that the Fastflow valve has swapped the reserve and closed positions.

Finally, a SCK-Ancillotti has just been installed and then our floor is ready.

Cleaning is only done at the CS in Ried.

3 replies
  1. Matthias
    Matthias says:

    Hello! Eextreeeem cool project and VERY cleanly done! RESPECT! Is this still street legal? Here in Italy it is unfortunately not possible to get such vehicles street legal. I'm in the process of converting my 50s Vespa in this direction. The body is already primed and the engine block is completely milled. I installed the disc brake system on my other Vespa, which I still use in traffic, to test it and only because of this little thing I don't pass the general inspection at the mechanic's .. Idiots. Anyway great project! Keep it up and off you go on the mountain pass roads;)

    lg

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