Ideas, Parts and Pieces

Parts and Pieces
1.1 After I left the army I went to university and while I was there my dad decided to buy a partially assembled motorcycle frame from a friend. The idea was that he and I, with some help from my uncle and various others were going to build a motorcycle, a custom Harley.
1.2 We thought we were getting a deal when we bought the partially assemble bike even though there was still a lot we didn’t have, an engine, transmission, controls and experience.
1.3 As the bike got built we found out that building a bike piece by piece is actually a very expensive proposition, more so than buying one ready assembled. Buying a bike partially assembled is even more expensive, especially as we undid a lot of the work the previous owner had already done, such as the paintwork. And because we had only part of an idea for the finished product there were quite a few learning experiences to be had. It was like me getting on my first bike and not realizing that steering a bike and stopping it were a special skill, a necessary skill.
1.4 We slowly bought the pieces we needed. Well actually, my dad slowly bought the things we needed while my uncle and I put the thing together. Some of the parts where brand new and some parts had probably seen the insides of several bikes. Several parts had to be modified to fit. But we got it together eventually and the day came when we tried to fire her up. We put fuel in the tank and pressed the start button. The starter motor turned but there was a noticeable lack of thunder. Though the starter motor was turning it wasn’t turning the engine and so the engine didn’t start. We wondered what was going wrong.
1.5 The problem was that the starter motor wasn’t turning the clutch.
1.6 There’s a little gear that slides out of the starter motor when the starter motor turns. It catches the teeth of a gear wheel on the outside of the clutch basket. When everything is working perfectly the starter gear is supposed to engage the teeth on the clutch basket, which then turns the motor and ideally starts it.
1.7 After scratching our heads my dad and I realized that whoever had the clutch basket before us had modified it so that the ring gear was in a different location. The starter gear popped out to a position where the clutch basket gear was supposed to be but wasn’t.
1.8 We took the clutch basket to a mechanic who re-welded the gear on to the clutch basket at the correct location. Excitedly we took it home and put the bike back together again.
1.9 Alas the bike still would not start.
1.10 Now the starter gear was engaging with the gear wheel on the clutch basket but while the starter was turning the clutch basket still wasn’t.
1.11 The starter motor was also second hand. We discovered that its magnets were switched so it was spinning the wrong way. We took it apart and reversed the magnets so that the starter spun the right way. Now when we tried to start the bike the engine turned over but the wires from the battery to the starter smoked. So we had to put thicker wires on the starter so it could get enough juice. After repeated test runs the bike again wouldn’t start. It took us a while to figure out that the bike had run out of gas.
1.12 I learned a lot working on that bike. I became conscious of the smaller ideas of a motorcycle and how those ideas relate. The starter gear comes out a set distance so it meshes with the clutch basket. The starter has to turn a certain way. I also learned that it’s fun figuring out how things work, but more so when I am not endangering my life.
1.13 Now that we know what it’s like to build a bike my dad and I agreed we could do much better if we ever do it again. We understood the pieces of a bike and how they go together so that now we can make another one if we choose. Now all I had to do is learn how to ride one.