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A few more bits done over the weekend and yesterday. Finally started work on the other side of the chassis which was in a worse condition than the other side, we replaced the side in three sections so that the chassis didn't twist. Just before welding in the last piece. Finally finished all of the repairs on the chassis, it just needs its final coats of primer and then I can start on the yellow paint With thanks to my grandad the tyres have been taken off the rear wheels so I can start cleaning them up. Some more bits sandblasted

Did t'other side of the wheels this evening...

Are you sure that coupling's strong enough?

Thanks Chris

Yes looking at it again its got the same running gear and chassis as that blue and white huffy I had

Thought id make a start at the front of the machine with the engine. First job was to remove the flywheel, then the fan housing. I ideally would of liked to of remove the silencer, however it is fused to the cylinder outlet in a big way! So instead had to remove the timming chain cover and jiggle every thing off in one lump. At first glance the piston doesn't look too clever, however previous experience tells me that with a light polish and a hone of the cylinder the engine will run just fine. Will have to give the aluminium a big clean up tomorrow, then I can start reassembling it all once ive obtained some more thin gasket paper to remake a couple for the engine.

These shots are how the clutch and flywheel looked when I first split the engine off the gearbox. The early type clutches don't appear to have the locking wire like the later ones so will be reassembled with a good dollop of loctite on the threads to make sure.

Its good to see you back in the 'orange' Gareth

There's a few images that may also help in this thread- http://myoldmachine.com/topic/1675-kohler-k-series-starter-motor-issues/

The objective is to insulate the feed to the brushes from the starter body so, as you say the plastic/ fibre washer goes on first, then the steel washer and nut. Don't over tighten the nut or twist the stud connected to the brush connection while tightening the nut. Then fit the wire form the solenoid , possibly with a spring or star washer and finally the nut - again beware of twisting the stud while pinching it up.

Rims split, old tyres off, rims cleaned up and first primer coat on...

Almost done just need to talk to Titch about a decal...

Looking a lot better now mate, quite a transformation from when i last saw it, well done