This is my next project.......... Its another Freebie, although not complete (missing the back end, rotors and shaft) Its fairly sound. Lots of original paint and no serious rust issues. The engine appears to be missing the exhaust and the air filter. I dont know how long this has been stood, It has some compression but think for my piece of mind I will strip it down and rebuild it.

Yes Martin, the tyres are very good! Not much wear which makes me think its not been worked too hard. Another good thing is there is no play in the wheels either.

Here are some pictures of the dismantling...... This first picture shows the rocker cover removed. First impressions would indicate something amiss with the exhaust pushrod, its not seated under the rocker arm. Hmmm?

some more photo's as its taken apart.......

There was a huge amount of sticky oily mess over the bottom of the engine.... so into the parts washer, and its come up really good. Lots of original paint and virtually no rust!

The valves after a clean on the brass wheel..... and a comparison between a BJ valve from a Gem with the Villiers valve from the Bantam...... 

hi darmic may be able to help you with rotor box ashgive me acall 07922128303

[QUOTE=daviddale]Hello, I have one of these machines myself, they have an overhead valve engine as opposed to the older more common side valve ones. Mine despite a strip down clean up and fresh oil etc good spark after a new coil too but engine does not turn as freely as I'd hoped, no damage or partial seizures as I can see or feel, but pulling it over is a bind, I have had it running for a few minutes at a time, but I need to get around to making a new throttle cable one day, carb end is just a tiny piece of solder, no nipple, how do I cast one on? I suppose I'll end up putting some copper wire around cable end and filling with solder, somehow,DD.


Try here, you can build your own.  http://www.vehicle-wiring-products.eu/VWP-onlinestore/motorcycle/controlcable.php

Phil

I use universal bicycle brake cables, Wilkinsons sell them for about £1.14, they have a pear nipple on one end and a barrel nipple on the other. The nipples can be re-shaped, slid up the cable to where you want them.
I would advise against braze or silver solder for cables, the heat affects the temper of the cable and when I was running a Norton motorcycle the clutch cable used to break near the nipple where the cable had been weakened. Soft solder with an iron is best.

This link may be of some use soldering a cable niple

Get some gasket paper, Ive got various thicknesses from the bay in the past. Draw around the Rocker cover, then draw a parallel line about 4 or 5 mm inside the outer one. Then cut out with either a sharp stanley knife or some good scissors, voila!
Ive got to either make a new magneto back plate gasket or order a full set up for mine as there was an oil leak from that area.

Also cleaned up the flywheel and the rope starter too. Its all in remarkably good condition. I think this machine has been stored inside most its life, as all the parts are in so much better condition than my Gems were. 

Gaskets sets are available from Meetens in Gosport - got one for the Mk15 on my Auto Culto Junior last September. The set was made up whilst I waited, and they are happy to do individual gaskets.

Jim.

That's a good link with good advice. If the nipple is slightly countersunk and the splayed end of the cable filled with solder the splay can't close up and pull through. The wedging action of the splay is far more effective than just relying on the "glueing" of the solder. Can't beat good old Bakers soldering fluid for cables!
Central Spares used to sell a solder pot but I see that it has disappeared from the current catalogue. All the ones from UK sellers on flebay seem a bit expensive for private users and not too sure about ordering from Hong Kong!

Took a trip down to Gosport today, to Meetens. Have purchased most of the bits to get the engine up and running. I say most as I realised when I got home I had forgotten the Airfilter....... Will have to phone tomorrow to order one!

Have been busy with the orange spray too..... Most the engine has been stripped, Etch primed and given a couple of top coats of colour.

Hi Darren, heres a few shots of doner machine you can have.