honda305.com Forum

I installed the new bronze bushing in the right side cover last night. It fits perfect...nice and snug. I coated the opening with red locktight and set the new bushing with a piece of wood dowel and a steel hammer. It took a few good whacks to get it in to place. Now that I know it is a good fit I'm going to have a few more fabricated to the same spec with my remaining stock.


P1060837 by flyin_, on Flickr


P1060835 by flyin_, on Flickr

The broken right cover was repaired with JB weld. It didn't set up quite as fast as I thought so it sagged a bit. I think I'll add another layer to thicken it up.


P1060840 by flyin_, on Flickr


I also removed the rotor with the harbor freight chain breaker tool. Worked great.


I made a new insulator gasket for the hi/lo switch out of a baby formula can lid. Although I think my switch has a lot of wear in it and I'm not sure if it will be as reliable as I want. The little ball doesn't detente in the housing very well. Maybe its not the correct size ball?


P1060842 by flyin_, on Flickr

Good info on the chain breaker.......is this the model?:

http://www.harborfreight.com/heavy-duty ... 66488.html

As long as the ball catches in the detents somewhat, you should be ok.

I coated mine with dielectric grease and it would probably stay in position even without the ball.

Yes, that looks like the chain breaker I have (that idea came from other forum members here). did you coat the plastic runner with dielectric grease? I suppose that would help hold the switch in position.

Yes, I coated the whole assy inside.

Is your spring long enough to push the ball out of the other side? It looks like it is.....maybe it's too weak? From your pics, I can't see any other reason it wouldn't catch in each position properly.