Solo 611 Twin lives again

[heimannm]

I had a problem with the starter in my Solo twin at the Baraboo event last August.



I took it apart then and discovered (for reasons that do not need exploring at this juncture) that only one pawl was engaging and overloaded the other.



I finally got around to fixing it the past week. First step was to get the broken piece out and make a new one.





Cutting the small groove for the "E" clip was tricking, but searching through the old hacksaw blade store turned up one with just the right thickness.



Parting it off was tricky too, but we managed to get the job done.

Mark

 

[heimannm]

The original design had the pivot for the pawl swaged in the starter pulley.



Since I don't have the technology to duplicate that, I decided to drill and tap it and hold it in place with a flat head screw from the back side.







To make sure it would stay put, I created a mold around the new pivot and used some JB Weld.



It cleaned up quite nicely.



Mark

 

[rwoods]

Great job - as usual. Ron

 

[heimannm]

The West German Engineers that designed the starter must have received a bonus for the number of parts they put in one design.

The pawls are held to the starter pulley with "E" clips.



The starter pulley has a roller bearing pressed in the center, and the spring is installed in a sort of cup behind the pulley in the body of the saw. Spring was fouled up when I got the saw.



Spring is in place behind the pulley, bearing pressed in the pulley, and the retaining ring holds in in place.



There are a couple of "brake springs" that install in the bore of the starter shaft that pull the pawls to engage notches on the crankshaft.





Pawls in place and the "E" clips installed.



Mark

 

[astnmacgto]

The original design had the pivot for the pawl swaged in the starter pulley.

View attachment 559306

Since I don't have the technology to duplicate that, I decided to drill and tap it and hold it in place with a flat head screw from the back side.

View attachment 559307

View attachment 559308

View attachment 559309

To make sure it would stay put, I created a mold around the new pivot and used some JB Weld.

View attachment 559310

It cleaned up quite nicely.

View attachment 559311

Mark

That's thinking outside the box! Good work

 

[heimannm]

Saw is back together and starts up quite easily. If you've ever seen one started (search Solo 611 Twin on YouTube) the starter rope is rather short as there is not room for many wraps so go carefully.



Mark

 

[svk]

Great work Mark! Were you able to figure out the leaky fuel cap fix yet?

 

[Chris-PA]

Very nice work, I like to see a good re-construction like that!

The West German Engineers that designed the starter must have received a bonus for the number of parts they put in one design.

LOL, the definition of German engineering!

 

[astnmacgto]

Very nice work, I like to see a good re-construction like that!


LOL, the definition of German engineering!

You bet! Even their cars are over engineered

 

[heimannm]

Roger Bennett gave me a good one while in Baraboo last year, all I had to do was put a chain together for him.

I found a few more photos from when I got the saw, shows the starter assembled.



And that's what it looks like under the starter.



Mark

 

[astnmacgto]

I know nothing about these, do they use two separate coils? Also does anyone know the degrees of rotation between fire?

 

[mgr]

180 degrees between them. They have 2 coils.

 

[CM76]

Nice work Mark - another informative thread. I have come across a few of these twins with starter issues.

 

[astnmacgto]

180 degrees between them. They have 2 coils.View attachment 559391

I had assumed so, but not all twin cylinders are 180° that has to be what makes it so smoooooth

 

[scottr]

Excellent repair Mark. What is the blue material you used to form the dam ?

 

[heimannm]

Scottr - Modeling clay, got it from McMaster Carr. I thought the blue color would make it easier to see and work with. I keep it double bagged in my shop refrigerator and it is still quite workable after two years.

Two coils, points, condensers.







Mark

 

[astnmacgto]

Looks similar to a rats nest haha, pretty neat I must say

 

[Conquistador3]

Allow me to compliment you on your work.
I have a lathe I inherited from my father but like Hell I'd be able to even start manufacturing parts like you do.

 

[sawfun]

Great job Mark. I have a fondness for that particular saw as it's likely the only one of its kind I will have ever seen in person much less been fortunate enough to make a cut or two with. That saw rocks .

P.S. Paint it yellow and maybe the gremlins will stay away.

 

[heimannm]

I know exactly why the starter failed as it did and I have great confidence that particular failure will not reoccur.

I did put a longer bar on it at one time but it seemed to have some issues with the oiler so I did not make any cuts with it.



Mark