Spare Wheel: Modify to Fit

After getting confirmation from the group, I knew I needed to widen the holes in the hub to get the outer spokes to fit.  I used the old weird hub from Viola to do some testing.  At first I just went straight in with the Dremel sanding tip to widen the hole.  But then I realized it's not so much the width of the hole but the the material where the spoke first hits.

So I came in with the Dremel at the same angle and direction the spoke would.  Just taking a bit of material out of the top of the hole allowed the spoke to slide right through.  I only did the outer holes, marking it as I went.

Also, a revised lacing procedure:

1. Insert all the inner spokes on both sides of the hub
2. Add nipples to all the inner spokes on both sides
3. Insert all the outer spokes on one side
4. Add nipples to those outer spokes
5. Repeat for the other side outer spokes
6. Job done!

Tutorial: Transmission

Notes and steps on removing the transmission.

Note Well:

1. Loosen the bolts on the front sprocket before removing the chain.
2. Don't lose the cylinder stud gasket when removing the cylinder.
3. Watch out for the both thrust washers.
4. Don't lose the pins on the shift drum when you flip it over.

Disassembly:

1. Remove the first thrust washer sitting on the big first gear.  (If it's not there, make sure it's not stuck to the crankcase)
2. Remove first gear.
3. Remove the shift drum along with both shafts.
4. Remove fourth gear.
5. Remove the second thrust washer.

Reassembly

1. Install the first thrust washer.
2. Install fourth gear (wear pattern will tell you right side up).
3. Install the drum with counter shaft in place in the "R" fork and just the third gear in the "L" fork.
4. Use an engine mount bolt to center everything.
5. Now install the main shaft - carefully so that it aligns and sets all the way down into the crankcase.
6. Install first gear (the wear pattern will tell you right side up).
7. Install the second thrust washer.

Disassembly

Reassembly