STEP -BYSTEP

Goldie leccy kicker

Classic Bike (UK) - - Classic Workshop -

STEP 1 ELECTRICS OUT

Re­move the fuse, then the bat­tery and Lu­cas volt­age reg­u­la­tor from in­side the tool box. Pear­son rec­om­mends a 12v Ex­ide ETZ14-BS re­place­ment bat­tery.

STEP 2 GET­TING HOLED

The hole for the ca­bles in the tool­box will need to be en­larged to 22mm to take the ex­tra wires. We used a hole punch. Use a rub­ber grom­met to pre­vent chaf­ing.

STEP 3 REG­U­LA­TORY BOARD

Fit the new reg­u­la­tor and so­le­noid panel in the tool­box. The V-reg II solid-state reg­u­la­tor converts Lu­cas 6v dy­namo to 12v (you could use an Al­ton gen­er­a­tor).

STEP 4 RE­ALIGN­MENT OF POWER

Fit new bat­tery in orig­i­nal po­si­tion but on end, with ter­mi­nals fac­ing oil tank. The starter mo­tor needs a neg­a­tive earth, so you will have to re-po­larise the dy­namo.

STEP 5 DO DY­NAMO PO­LAR­ITY

Con­nect neg­a­tive bat­tery ter­mi­nal to chas­sis, take off dy­namo D and F wires, con­nect a wire to pos­i­tive ter­mi­nal and brush it on F ter­mi­nal to cause a spark.

STEP 6 AD­JUST ELEC­TRIC BITS

Swap wires around on the am­me­ter so charge is not show­ing as dis­charge. Fit 12v bulbs (6v horn works with 12v). Put starter but­ton on ’bar, wire it to so­le­noid.

STEP 7 CLUTCH­ING AT IT

Bendix bear­ings need oil. Leaks can be pre­vented with im­proved Pear­son O-ring type slid­ing plate. While you’re at it, why not fit a Pear­son clutch, too...?

STEP 8 EX­POSE THE AREA

Re­move the outer pri­mary cover, clutch and pri­mary chain, cush drive with en­gine sprocket and in­ner pri­mary chain­case. Clean the crank­case where gas­ket fits.

STEP 9 MARK THE BOSS

The boss on crank­case car­ries oil feed to rock­ers on pre-war mod­els but was not in­ter­nally drilled later, so is re­dun­dant and gets in the way. Mark it with felt pen.

STEP 10 GET GRIND­ING

Grind off the part of the re­dun­dant boss you’ve marked, to al­low clear­ance for the starter sprocket to be mounted on the back of the new in­ner pri­mary chain­case.

STEP 11 ON GUARD

Tem­po­rar­ily fit new in­ner case; mark the chain­guard where it fouls the case. Take off chain guard and cut it so guard fits and won’t catch as sus­pen­sion bot­toms.

STEP 12 GET THE MO­TOR ON

Re­move lower gear­box stud and en­gine plate stud, and re­place with starter mo­tor mount­ing bolts. The starter mo­tor can now fit­ted, but leave bolts slack.

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