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General => Douglas Motorcycles - General Discussion => Topic started by: douglas1947 on 31 Jan 2017 at 05:45

Title: Air lever on AMAL 5/116/S
Post by: douglas1947 on 31 Jan 2017 at 05:45
On my S6 is the Air lever on AMAL 5/116/S missing. the carburettor is now working with a "normal"Air Slide, wire operated from handle bar.
I would like to complete the car to original standard.
Has anyone an idea?

Michael
Title: Re: Air lever on AMAL 5/116/S
Post by: Doug on 31 Jan 2017 at 19:10
Michael,

(https://www.douglasmotorcycles.net/aa-files/images/doug/2017/s6/s6-choke-1.JPG)

(https://www.douglasmotorcycles.net/aa-files/images/doug/2017/s6/s6-choke-2.JPG)

Behind the hole is a drilled well with a ball and spring to engage the detents on the carb. body.

I had to make a new lever (it had broken off) based on photos of others machines, but the hub is original.

-Doug
Title: Re: Air lever on AMAL 5/116/S
Post by: douglas1947 on 01 Feb 2017 at 05:44
Hi Doug,

thanks for photos and explanation.
The lever is not so easy to reproduce! I will think about it to have an idea how to manage. Do you use alloy?
Is the axle flattened for the air disc?

Michael
Title: Re: Air lever on AMAL 5/116/S
Post by: Doug on 01 Feb 2017 at 16:08
Michael,

The lever is brass. You could start by turning it in a lathe, file the part that transitions from circular to oval, and then bend the lever.

(https://www.douglasmotorcycles.net/aa-files/images/doug/2017/s6/s6-choke-3.JPG)

(https://www.douglasmotorcycles.net/aa-files/images/doug/2017/s6/s6-choke-4.JPG)

The shaft (axle) is not flattened. The disc is pierced and formed to fit around the shaft and held captive by two split pins. A flat and two screws would be simpler to replicate!

-Doug
Title: Re: Air lever on AMAL 5/116/S
Post by: douglas1947 on 02 Feb 2017 at 16:13
Doug,

thanks for further photos and details.
I will start to find material and reproduce the parts.

Michael