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I next focused my attention on the carburettor. At some point in the machines past, it had lost it’s original carburettor, having been fitted with an Amal 348/7. Charlie was able to provide me with the correct model number, this being an Amal 244/544. With this information, I was able to quickly track one down at a classic motorcycle spares seller in the north of England, although on dismantling this carb, I found that the main jet had been damaged by over tightening of the float bowl fixing bolt. So, the hunt was on for another, which after several months was found on that well known auction site. The item was indicated as being for a Simar 56, but using information posted on this forum, the size of the jets would suggest it was actually from a Simar 35, as the main jet was a size 60 instead of a size 70. This carb was also found to be missing it’s float, so I decided to use the first carb purchased.
The size 70 main jet had a tubular extension at the inlet end, whereas the size 60 jet from the other carb does not (Carb 0001). I do not know what purpose this extension serves, but as this was the part of the jet that was damaged (Carb 0002), my only option was to cut it off (Carb 0003). A new paper gasket was fitted into the main body of the carb (Carb 0004). The idle and main jets (Carb 0005) were screwed into place using a 5mm square drive radiator key (Carb 0006). Two small slotted head screws hold the paper gasket in place (Carb 0007). Also visible in this picture is the needle holder and needle which allow fuel to enter the float bowl. The large brass plug which covers the jets was screwed into place (Carb 0008). According to the part list, this item is know as the filter adaptor and should have a filter gauze fitted inside it. Neither of my carbs contained this gauze, so currently none is fitted. The fuel supply line nipple was fitted, along with a fibre washer (Carb 0009). On the opposite side of the carb body, the tickler body was screwed into place (Carb 0010) and the tickler inserted through it (Carb 0011). The tickler is held in place by a 1.6mm diameter split pin inserted through the end that projects into the float bowl (Carb 0012). The float and float bowl (Carb 0013) were fixed into place by a bolt and copper washer (Carb 0014). The bolt screws into the filter adaptor, so it is important not to over tighten as damage to the jets could result. The last bits to be fitted were the throttle slide parts (Carb 0015, 16 & 17). I have deliberately left some parts off the throttle, as these will be fitted later with the throttle cable. The carb is fixed to the engine intake/exhaust manifold by two M6 studs and a copper gasket (Carb 0018 & 19). The gasket has seen better days, but it is still usable.Attachments:
A new paper gasket was made for the miller gearbox cover and fitted along with the three M8 studs and two locating pins for the miller shaft bronze bushes (Simar 0097), after which the miller gearbox cover was fitted (Simar 0098). Moving back around to the front of the machine, three M8 studs were screwed into the fan casing (Simar 0099) and the engine cowling installed (Simar 0100). Next to be fitted was the reverse motion clutch lever. The lever is held on the shaft by a 5 x 26mm tapered dowel pin (Simar 0101). If removing any of the three clutch levers, it is important that you establish which end of the pin is the larger diameter, so the pin can be driven out in the correct direction i.e. from the smaller end.
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Having decided that it would be a good idea to complete and seal up the rebuilt engine before I start more grinding filling and sanding, recent jobs have been to fit a new piston and rings ( thanks to Neil) Change the oil pump ( damaged flange ) rebuild the clutch and ratchet starter mechanism. Make up a new set of cylinder head studs. Make an adapter to fit a 12 tooth sprocket on the Lucas magneto.Cut out a set of new gaskets for the timing cover, barrel,final drives, pto and magneto( heavy felt). I have also painted all the track washers and one set of pads, the other set are ready to paint. One job I have been putting off is the engine cowling which was in a very sorry state, I soaked it in the acid bath, shot blasted it and then set to brazing up all the stress cracks and rust holes before giving it a preliminary panel beating to get it back into shape. I also annealed the whole thing to make it less brittle. Today I put it all together and surprisingly it looks ok.
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