400 restoration project

[Barrie2777]

I used to buy the cole herse stop switch but then they changed their policy so that I could ably buy 100 units at a time. JAYVEE found them at Canadian tire part #UN28770.

Sharp eyes Pete, that bolt is the crankcase drain plug and cannot be thrown out. Since the carb is operated from the vacuum created in the base of the engine, without this plug there will be no vacuum. The engine will never start. That engine has to come out again.

I have several machines which have the choke cable holder and they look very factory made. Some machines do not have them but it is very easy to make.

[Barrie2777]

The dash items are finally all in place and looking very original. Even the light switch has the little ball on the end of the toggle.

[Barrie2777]

I'm missing the shutoff valve on the bottom of the tank before I can add gas to the tank. However I couldn't wait any longer to hear this engine run so I put I little has down the carb. I was a bit cautious on the first tug for fear that the timing Wasnt correct resulting in a kick back pulling my shoulder from its socket. The second pull it fired and ran for several seconds.... my shoulder still in its socket. It was the most wonderful sound in the world!! Somewhere between a Harley and a 400 hp car with Thrush mufflers. When I get the shut off valve and it runs for a decent amount of time I'll post a utube video.

[Barrie2777]

This is technically the last part I had to buy. I am amazed how so many parts were stock items and have not changed to this day. Hardly able to hold in my excitement for starting this new machine, I secured the shut off valve, poured gas in the tank, connected the gas line and pulled the crank.....nothing. Cranked more.....nothing. Poured some gas down the carb just to get things going...ooops too much came out of the can , filled the carb throat and I watched as all that gas seeped away into the cylinder. It may sound like a Hitchcock horror story and probably is close to it but I removed the plug, cranked some more to expel gas, replaced the plug, cranked....nothing. This engine just wont draw the gas! There has to be a carb problem. I checked the pop off pressure and found it to have none!! Since the pop off pressure is checking at what point the needle comes off the seat, I think I found the problem. Took the carb apart (did not remove it) and found the needle stuck open.... strange. Loosened it and reassembled the carb, checked pop off pressure..... none again!! Took the carb apart, removed the needle and exchanged it for one in my "misc carb parts box" (everyone has one for those parts you remove because they are no good but too good to throw away!!), reassembled the carb and cranked.....

[Barrie2777]

https://youtu.be/X72o9tUH-Yk

[Barrie2777]

I cant wait for those "how many cranks does it take to start on a cold morning in January " competitions in Val des Bois!! This engine started in about half a revolution.

[Barrie2777]

This is the last item to be rebuilt and painted. It was on another engine. I was unable to remove it so took it to a friend in town. Luc can fix anything or build anything mechanical or engine related. He took it off with out thinking about it. Here is another clutch removal system to add to the list we already have. This one seems the easiest. Fist you find a fire extinguisher with CO2 in it. This stuff is cold so give the primary clutch post and crankshaft end a substantial blast to cool it down then pour some hot water on the post. A tap with a hammer on the loosened clutch bolt and that thing pops right off.

When this clutch was dismantled, I discovered the pins retaining the counterweights were worn badly. (see the third photo). The pin on the right is worn while the pin on the left (from another clutch) is in perfect condition.

[jayvee43]

Love the sound of that engine Barrie. You don-good. Its Idling so gang low. You timed it perfectly.

I really enjoyed watching your restore this summer,. I am starting to miss my new project 502.

Enjoy

Jesse

[Barrie2777]

I put a "MINI TACH" on it tonight. It is idling at 850 rpm.

[Barrie2777]

Bell housing rebuild is simple providing the counterweight pins are okey and the contact tips of the counterweights are not worn. I put in four new washers and four new cotter pins after replacing the pins. Make sure everything is well lubricated then reassemble.