Adding an Alton starter to my café racer

Joined
Jan 22, 2008
Messages
2,585
Country flag
This is a link to my earlier thread with my café racer all done cafe-racer-all-finished-t4710.html?hilit=finished

I put it in storage because I had other projects, first my Commando café racer cafe-commando-build-thread-t8372.html and then renovating a restaurant for my daughter and building a bar for a friend, also it was a bear to start, the only way I could start it was to use a borrowed roller starter which spun the back wheel or put the track stand and kick like mad. The main reason for hard starting is the lack of a center stand and short clipon handlebars which do not give any leaverage to keep the bike upright when kicking, not to mention getting older every day.

I had put the bike at the Montreal moto show when I finished it, the first year, I rented a small enclosed trailer from U-haul, but the second year, I used my own MC trailer which is all open, even if on both the to and fro the weather was nice, if you call sub freezing temperatures nice, the sun was out and the roads were dry. Here salting the roads is a way of life it eats whole cars in a very short time. When I got the bike back home, it stayed in my garage until the next autumn and I took it to my friend's garage for storage to give me room to make my Commando. His storage area was not heated and there must have been many days where condensation hit all the metal parts, well the nice steel surfaces had a little bit of salt picked up from just two trips of less than 20Km from my house to the exhibition hall and back. After a couple of years in storage, what I got back home was in a bit of a sorry state, the kick start lever was very pitted, the shocks were really rusty and many other steel or chromed bits had rust. The bright shiny aluminium was now dull and I even found sunflower seeds in the battery compartment from rodent activity.

I will add pictures as the installation progresses, so far it looks good, I made a few modifications but I think I should have this on the road by spring (famous last words)

Adding an Alton starter to my café racer


Here is a picture with all the primary drive taken off

Adding an Alton starter to my café racer


Jean
 
That is awful Jean, what a mess the salt makes.
I did a similar thing two years ago. I rode my Egli to a New Years day function on what I thought were dry roads. Unfortunately I must have encountered some of the liquid stuff they are using here now. I parked the bike for a couple of months then brought it out to replace the 1000 CC Rapide engine with the new build 1360.
The aluminium wheels were deeply pitted as was the primary and timing case on the Rapide engine. With a lot of polishing I got the engine cases looking good again, but the wheels will never be the same. Fortunately that bike has a stainless steel frame or the damage would have been much greater.
That liquid road salt, said to be made from beet juice, is at least as nasty as regular old road salt, maybe even worse!

Glen
 
Yep, salt, even a little bit will really screw up steel and aluminium parts :(

Jean
 
Jeandr said:
Yep, salt, even a little bit will really screw up steel and aluminium parts :(

Jean
Sorry to see the damage done to such a special, "special". thanks for the link to the build pictures, it is truly a work to be proud of. Love the adaptation of the alternator :D Cj
 
Some progress was done...

Since I am putting on the Alton starter, I had to install their inner primary cover and the parts I had on hand was the stock triple row primary chain. I have nothing against the stock chain and I kinda like the fact that the parts inside will have some lubrification, even if it is minimal. First order of business was to mill adjustment slots in the engine plates.

Adding an Alton starter to my café racer


Test fit of the inner primary, looking good, nothing too out of the ordinary from a Commando. It is a good thing the engine was tilted à-la Commando otherwise it would not have fitted in place.

Adding an Alton starter to my café racer


This is a tight fit, I had to shift the transmission 1/16" towards the right (in the picture) as well as cut the pulley guard and the carrier sprocket a bit.

Adding an Alton starter to my café racer


These are my chain adjusters, (idea from Ludwig) no room for anything else

Adding an Alton starter to my café racer


The rib had to be machined off because the pulley is of a much larger diameter than the sprocket

Adding an Alton starter to my café racer


This is my new swing arm support bracket, on the old setup, I had a plate from the engine to the frame, that is now gone and so is my outrigger transmission bracket

Adding an Alton starter to my café racer


Jean
 
This is the Alton's sprag bearing...

Adding an Alton starter to my café racer


I put in flat headded screws to give me a bit of room...

Adding an Alton starter to my café racer


To add the crank mounted ignition pickup

Adding an Alton starter to my café racer


I even had to remove the degree indicator from the outer cover in order not to come in contact with the ignition sensor.

Adding an Alton starter to my café racer


I will post more pictures as I make progress. Most of the work I have to do is to repair the storage damage (rust), redo the electrical system, polish and shine. My battery is on order, should be coming in soon.

Jean
 
I ordered a Ballistic battery to have enough grunt to spin the starter. The Shorai was a bit bigger and it is fortunate that the Ballistic is a bit smaller because I only had to hog out the inside of the battery tray for it to fit inside, the starter relay will be placed right next to it and I moved the fuse block and the relay to the back of the battery carrier.

Adding an Alton starter to my café racer


Adding an Alton starter to my café racer


Adding an Alton starter to my café racer


Now I am looking into voltage regulators...

Jean
 
bwolfie said:
Jean, looking good except someone has stolen the top end off your engine.

Ahhhh (If I was stronger, I would have taken it out in one piece :wink: )

Jean
 
I started reassembly...

Here the Alton inner chaincase and the starter gears and chains are in place

Adding an Alton starter to my café racer


Shimming the stator with the supplied shims

Adding an Alton starter to my café racer


My primary chain adjusters in place

Adding an Alton starter to my café racer


Clutch nut, seal and throwout bearing nipped and locked in place

Adding an Alton starter to my café racer


Sachse ignition pickup installed, I carved a window to see the timing marks on the rotor and I will add timing degree marks

Adding an Alton starter to my café racer


Jean
 
That's beautiful Jean, I wish I had your ability to get things done that nicely...
 
Started to do the electrical system,

The regulator in place

Adding an Alton starter to my café racer


The battery box...

Adding an Alton starter to my café racer


Daytime running light

Adding an Alton starter to my café racer


Jean
 
Timing scale... for the inquisitive ones, I just printed out a timing disk, cut a section out and glued it on the rotor with silicone, then some clear silicone on top of the paper to make it oil resistant. If it peels away, I can just print out another one :wink:

Adding an Alton starter to my café racer


Jean
 
Some progress was done assembling the different parts and I started to make a better looking exhaust pipe.

Adding an Alton starter to my café racer


Jean
 
Back
Top