Tonti stuck clutch

[HRC_V4]

I wish I could find the picture of when I pulled the clutch off my Quota, super simple, had it done in an afternoon.  Not in a big hurry on this project, I still have not order parts yet, so just working on it when time permits.  Spent an hour or so on it today, pulled the starter, front wheel and fender, clutch cable and then strapped the engine to the stand. Only three major steps next, front crash bar, center stand and transmission top plate.

[HRC_V4]

The next steps..

[HRC_V4]

The California II has been crabbed!  Not a bad job, it is giving me a reason to address a few things, I'm going to go ahead and replace the throttle cables, clean up some surface rust, deep clean a few hard to get places.  I have the clutch upgrade kit on the way, the clutch job transmission seal kit, rear main engine seal and a couple of other things.

[HRC_V4]

Looks like I am missing the output shaft seal....

[HRC_V4]

Does anyone have instructions on the swingarm install? I measured mine before I took it off, they were not equal side to side, which I thought was the way to do it, but with the missing seal, someone might have been in here before.

[Pressureangle]

5 minutes ago, HRC_V4 said:

Does anyone have instructions on the swingarm install? I measured mine before I took it off, they were not equal side to side, which I thought was the way to do it, but with the missing seal, someone might have been in here before.

Just center it up and you're good. Run it up and down just to be sure something won't snag, but I don't think there's enough latitude for adjustment to cause any trouble. 

[HRC_V4]

The two clutch discs are stuck to the intermediate plate. I have not tried to separate them, but a fair amount of rust.  I'm sure it will all clean up.

[motortouring]

 

15 hours ago, HRC_V4 said:

Does anyone have instructions on the swingarm install? I measured mine before I took it off, they were not equal side to side, which I thought was the way to do it, but with the missing seal, someone might have been in here before.

The formal method is to use an axle through the support bearing in the swingarm that has a ring to centre on the outgoing axle of the gearbox. 

Horizontal adjustment is with the swingarm bearing bolts and vertical is by fixing the bolts of the underframe and the battery plate.

In practice centering the swingarm axle bolts (on the side) is the way to go.

 

With many thanks to JCK from NL

Edited August 12 by motortouring

[HRC_V4]

Parts came in yesterday, so back on the project.  It took some effort to split the clutch discs from the intermediate plate, but they look really good, so spare parts.  Installed the new clutch, new throttle cables, transmission seals, rear main seal, float valve, breather hoses, air filter, etc.  The swingarm and the center stand were PITA, but they are on now.  Hopefully more work tomorrow.

[HRC_V4]

Finally got a few miscellaneous parts and got it back together. Took her out for a test ride and she did great, just a quick ride around the neighborhood.  The new shocks are nice, my front wheel seems good with the new spokes, she shifts smoothly and rides nice. I'm going to need the OEM style seat, this one has me a little too far forward.  I changed the diff fluid, it was low, which probably explains the gear oil in the driveshaft housing. Any thoughts on what would cause that? I see a couple of orings in the parts diagram.  Waiting on a new clutch cable, this one is adjusted all the way out. I'll post some good fall pictures in the coming months.

[pete roper]

Have you converted it to a trike? I’m assuming you mean the bevelbox?

The pinion bearings on the Tonti’s aren’t sealed and if the shocks have collapsed or shorter ones are fitted the angle the swingarm operates at means oil gets flung through them and pools in the swingarm. This would probably also explain the low volume in the bevelbox itself.

The two O-rings? One goes over the pinion carrier and acts as a crush seal in the chamfer at the front of the bevelbox housing. The other one goes in the groove in the front face of the pinion holder and acts as a crush seal against the end of the swingarm.

[HRC_V4]

10 hours ago, pete roper said:

Have you converted it to a trike? I’m assuming you mean the bevelbox?

LOL, no trike...  I knew diff wasn't right, but yes, the bevelbox.  Thanks, I'll let it ride this way a while and keep an eye on the level.  Not sure the whole story of the bike, but originally from Switzerland, then was in NY for a while, but I got it from a little machine shop south of Morgantown, NC.