Risky's 2008 Ambassador II Whizzer Rebuild

[Wrench]

FINISHED (now for the fun part to get it running)

It has come a long way.....had it running last week before I finished it, but think I flooded it last night.. not trouble with the starter motor... which is the only thing I don't like as it is the only way to start this engine. enjoy!

She's Beautiful I love the Paint & Pinstripe - Shes Clean like new, Hurry up and sell it JKN

BTW do you have a belt guard,

 

[Risk Man]

Well, not for sale yet. I have the original belt guard which refurbished, but don't like the silver paint job how it came out. Actually don't like the guard it self. So, I am going to make a "skeleton" guard out of aluminum to wrap around the belts at each end. Have an example I found someone made.

But, big story is my starter Motor is dead. It over heated last night trying to start the bike and as it was cooling down it still worked. Waited to later and would not run. Took it apart this morning but it back together and it ran without load. Put it back on and dead. Took it off, took it apart and put it back together but nothing. Going to either get it rebuilt (have an armature works here for larger motors but he is old school so may be lucky he will work on it.

Reaching out to Joe Lin and other sources (calling Q) to find a replacement. It is just like a gy6 but the case and sprocket are unique
So will ride the Gator bike to the car show tomorrow, and the chopper goes in the storage side of the shop until I can get a motor. I knew from the get go that the starter system was the Achilles heel of this build..not really the CVT which can be overcome.

 

[Risk Man]

She's Beautiful I love the Paint & Pinstripe - Shes Clean like new, Hurry up and sell it JKN

BTW do you have a belt guard,

Thanks! I am very happy with the outcome except for the major problem to get it running.

 

[Risk Man]

And by the way, I found out you can buy special paint for carpet and vinyl from the auto body paint supplier! The seat is the original black seat with the tear. Repaired it, cleaned it and painted it. Came out fantastic.

 

[Wrench]

Skeleton Belt guard sounds cool also a painted red guard would look good

 

[Risk Man]

Skeleton Belt guard sounds cool also a painted red guard would look good

 

[Risk Man]

Starting to wish this project was an NE5 instead of an Ambassador.

These bikes are such low production, information and Parts are scarce even from the Experts, Ray, Quenton and parts hoarder Wayne in Northern California. I am paying Wayne 6 times the price of an identical starter motor .... without the Bracket welded on the case and the flat shaft with timing belt cog.........

 

[Risk Man]

So, I bought a stock GY6 starter motor ($27) that was exactly like the Ambassador motor except for the lack of mounting bracket and screw drive instead of hub mounted on flat sided 1/2 inch shaft.

Took the armature and the front end and used my case with mounting bracket to marry it... Worked fine. Now to adapt the flat sided half inch bore timing belt gear to it which also was screwed into the end to retain it.

I built of the geared shaft of the replacement with JB Weld and drilled out and tried to tap the shaft for the 5mm screw. Drilling went well, but Irwin Tap broke off after about 1/4 of the way in.... used their suggested 19 drill... Darn it! now I am screwed..

Went with plan B and free hand ground down the flats on opposite sides of the built up shaft and timing belt pulley slipped on nicely. No screw to retain so i went with the Bearing "thread retainer" glue I bought for the CVT shaft.... it worked fine.

 

[DieselTech]

So, I bought a stock GY6 starter motor ($27) that was exactly like the Ambassador motor except for the lack of mounting bracket and screw drive instead of hub mounted on flat sided 1/2 inch shaft.

Took the armature and the front end and used my case with mounting bracket to marry it... Worked fine. Now to adapt the flat sided half inch bore timing belt gear to it which also was screwed into the end to retain it.

I built of the geared shaft of the replacement with JB Weld and drilled out and tried to tap the shaft for the 5mm screw. Drilling went well, but Irwin Tap broke off after about 1/4 of the way in.... used their suggested 19 drill... Darn it! now I am screwed..

Went with plan B and free hand ground down the flats on opposite sides of the built up shaft and timing belt pulley slipped on nicely. No screw to retain so i went with the Bearing "thread retainer" glue I bought for the CVT shaft.... it worked fine.View attachment 222482

If you take a good small center punch. I'm talking snap-on brand. You can sharpen the point, making sure to keep the punch cool while sharpening.

You can take the center punch & break the tap apart in small pieces, then use compressed air or a mag to remove the tap pieces.

This is no fast procedure, but can be done.


There is also this option: Broken tap extractors , a good set is expensive.

 

[Wrench]

To bolt on that starter gear, a piece of All Thread could be Tig Welded to the end of the shaft,
Yeah, Heat and High Voltage can ruin the starter magnets but... There's not much to weld
Take the armature out of the housing then Tig Weld a little bit at a time and let it cool before welding more
It should be fine