fibersport

If you put a smaller pulley on the motor, I think 2" or 45mm is the smallest they make, it should slow it down just right. I also removed the brake shoes on my analog servo motor as well, made start up much predictable and smoother.

Nice looking machine, easily will last another 60 years. There is another recent Pfaff thread, there are some great links to information on the Pfaff machines.

I use 135 with a 22 needle on mine, works very well. Go here and search for manuals for the 1245. https://www.pfaff-industrial.com/en/support/downloads/technical/documentsearch The service and instruction manuals are what you want. I wouldn't get too hung up on the letters and numbers of your machine, yes, nice to know but you're never sure if it was changed somewhere along its life.

Give it a good cleaning, oil it up and adjust it. There is a manual for setting up a 1245 which can be used for the 545, plus there are copies of the 545 manual but honestly the 1245 manual is much better. Your problem looks like the tension is set wrong. The 545 is a great machine by the way although parts are sometimes hard to find and are usually pricey. Give this post a good reading as well:

I agree on the servo motor. I installed a Consew CSM550-1 analog servo motor on my Pfaff 545, held off with installing the speed reducer and have found it to be just fine. If you go with the Consew servo motor CSM550-1, two suggestions: 1. contact Bob at Toledo Industrial (advertised on this forum) 2. remove the brake shoes from the motor, it makes startup much smoother. I wrestled with going with the analog vs the digital servo motor and opted to save a little money by going analog. Sometimes I do wish I went with the digital so I could install a needle positioner. If you go digital, Sewquiet or Sailright 12 coil motor would be my choice. I've been using mine for some Jeep seats in leather, my next job will be an interior for my boat using vinyl. The Pfaff is a great machine, you really lucked out on that one. Let us know the specifics on the machine and holler if you need help, always someone here to help out.

I'm going to suggest looking at anything that rotates, any excessive clearance will make that type of sound on other mechanical things. Have you looked for excessive backlash in the gears underneath - and I'm assuming the Juki's ahve gears.

Glad it was simple! I had a 145 but was able to find a 545 very close to home in better shape. Finding a newer 1245 would be my ultimate machine. Overall they are built like tanks, once you set them up they go for ever.

Could the safety clutch do that if there is a bunch of thread wound up around the bobbin holder? My guess a good cleaning and adjustment is all it needs.

I have had good luck with this company: https://www.amazon.com/stores/ckpsms/page/8C8B8C59-BE53-42E6-B404-8E5D05BAEFB8?ref_=ast_bln&store_ref=bl_ast_dp_brandLogo_sto

You could adjust it for the shorter needles, the 190 system aren't very common, I had a 145 H4. The 135's are a little more popular but there is another that is used on the Consew's but I can't recall what it is, that might be the way to go. Good luck with your search.

Sorry I can't help you with a bar but have you thought of having yours re-tapped? I can't recall if it's a through hole but if it is, you can always insert the tap from the backside which might give you a better chance of hitting the original threads. If this isn't your cup of tea, maybe a friend who knows machinery can help you out? I think the thread is a M3.5. You might try this one: https://www.cutexsewingsupplies.com/products/cutex-needle-bar-part-number-91-710650-92-compatible-with-pfaff-145-335-545-sewing-machine?variant=42810286604531

I wouldn't take it all apart, just enough to get the gummed up stuff cleaned out. I have a 545, also had a 145 that was pretty dirty. I flooded parts with WD40 and 3 in 1 oil to get everything all cleaned up, especially on the 145. Search for the 1245 setup and adjustement manual, most of it will apply. I have a lot of documentation that I can send you if you want, let me know.

I see my photos didn't upload, wil get them tonight.

I have a couple more but I can't upload them right now.

Managed to take these pictures with a scale in the background, let me know if these are OK or do you want more.