Loose Bruce

Hi guys. Would any of you happen to have a Merlin, who could maybe tell me what the complete part number is on the Kokusan CDI. I do know that Merlin used two systems, Kokusan and Dansi. As you can see from my photo, I only have CU 21. There are more digits or numbers after that. Thks Bruce

Good Day , I have a 350cc Merlin Cagiva which has pretty much overnight developed an engine issue. It will now not fully rev. The engine sounds muffled when revved, like if the exhaust silencer was blocked ( which it is not). I have checked the carb, cleaned the jets, tried different jets and even tried a new carb. This did not solve the issue. I checked the coil and tried a new coil. This did not solve the problem. I checked the stator and tried various advance and retard positions. This did not solve the issue. For my sanity, can anyone explain to me how the CDI works? The engine when was running fine, the stator was pretty much on TDC. Does the CDI then deal with the timing of the spark when the engine revs are increased. Not having an useful specs for the engine, I assume that TDC is correct. Whilst taking the flywheel on and off, I did detect some movement in the main shaft. I doubt if the main bearings have ever been changed! If the bearings are faulty and subsequently the main seals may be faulty, could this possible be the source of the problem ( taking in air or pushing out fuel ). The engine is not smoking excessively, but maybe that is due to bearing/seal failure only being on the flywheel side. I have approached Rex's Speedshop for advice, but before I part with a small fortune on a new ignition system, I thought I would ask you knowledgeable guys for advice. Kind Regards Bruce

Hi All, I am in need of a new alloy ( if possible ) rear sprocket for my 1969 AJS 37AT that I am busy building. I have attached a sketch of what I need. If I can get only get one that is close, then I am sure I can modify it to suit. The existing sprocket has been made from two steel sprockets and weighs the same as a baby hippo !! Has anyone had a bespoke sprocket made, and if so, where. Or can anyone point me in the right direction. Thks Bruce Watts AJS 37A Rear Sprocket.pdf

Hi Guys, I thought you may be interested in seeing the finished product. Chrs Bruce

Hi Chaps, My next question please! Does the clutch have its own oil bath or does it share the gearbox oil? It looks to be the latter, because I cannot find a clutch drain or level plug. The bike manual is a bit vague. It just states that the "gearbox" should have 900cc of SAE 80. Thks Bruce

Hi Guys, It worked perfectly. I did a temporary "sticky tape" test and the engine started 2nd kick. I will now use the permanent glue. Thks Bruce

Good News, bad news. So, I managed to get the flywheel off with my homemade puller, only to be met with a corroded and dirty set of electrics, but even worse are the loose set of magnets. They have all shuffled around, not leaving a gap in between. The corrosion has obviously weakened the original glue. Simple to clean and re-glue, if you know where to glue them. I guess they are to be equi-spaced around the inside of the flywheel, but where? I would think they have to be correctly positioned in relation to say the keyway. Does it make a difference if you just simply set them equi-spaced. Maybe not. There does seem to be a mark where one magnet may have been, so if they are equi-spaced, I can position the other three. Bit of a risk, as you only get one chance to get it right! Does anyone have a picture of said flywheel with magnets installed, or any advice. Maybe put them in with some good double sided tape or silicon. Once I find the correct position, glue them in properly.

No such luck ! I can only assume that I need to make a flat plate puller, drill with 3 holes to match the threaded holes in the flywheel. Then drill a centre hole, weld on a nut, then ues a bolt to push to flywheel off. This maybe easier said than done.

I just spoke to Sammy on the phone, and he seems to think that the flywheel has an inner threaded section for a screw-in type puller. Will check tomorrow to see if the Maestro is correct.

I watched the video, but it looks as though Sammy had previously loosened the flywheel, hence it came off so easily. It would also appear that a Motoplat ignition system was installed, which is different the what i have on my bike. It is not a 2 part flywheel. So I am going to make up a removal plate with centre bolt to remover the flywheel. When I manage to start the bike it is blowing back through the carb, which makes me believe the timing needs adjusting. Not sure if it needs to be advanced or retarded. It may even be some form of pre ignition. It could also be a faulty CGI box. The list is endless. I will check the Suzuki system, should I need to replace the existing. As for using a strobe, would I not need to find some timing marks on the flywheel? If all else fails then Sammy Miller lives 20 minutes down the road from me, so I may ask his advice. Thks Bruce

HI All, Does anyone know how to remove the flywheel on the Hiro engine. It seems to be in two parts. Does it need a special puller? I am trying to get to see the ignition system to see if it is set correctly, which leads to me next question. How do you set it?? Thks Bruce

Can anyone suggest a good replacement for the existing Amal 626 carb Mikuni, OKO or similar.³

I am giving the forks on my Merlin a service. The forks are telesco, which I am not familiar with. Does anyone have a tech manual for them? Only one leg has a spring with a pre-tension mechanism. The other seems to house some sort of damping/rebound mechanism, with a 1 to 7 dial. My main question is how much oil in each leg and what grade? What does the 1 to 7 dial do? Chrs Loose Bruce

Hi All, Can anyone help me out with a copy of a user manual for my Merlin trials bike? It is just the basic data I need and in any language. Thks Bruce

Hi Lee, Here is a pic of mine, which has been confirmed as a genuine Comeefords Cub. Get in touch with Mike Estall at Tigercubclub.com. He can confirm if yours is indeed a Comerfords and you can get a dating cert from him. Shout if you need help. Bruce