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Old 12-09-2011, 09:08 PM   #31
wanna bECO
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nah, I'm just irish cuz my dad liked the red headed lass that was my mom, I've only ever drank in the states, and I've been kicked out my share of bars here, so I'm sure i'd lose a tooth or two if i were to ever get to the old sod.
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current stable

'94 Harley .... a blue one
'82 Honda passport
'87 Honda spacy 250
And an E Bike
85 spacy 250
81 passport (in pieces, many parts for sale)
The hit's just keep coming.. bought another 81 passport (11-28-09)

http://tiny.cc/ITgetsBETTER
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Old 12-10-2011, 07:18 AM   #32
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Quote:
Originally Posted by wanna bECO View Post
nah, I'm just irish cuz my dad liked the red headed lass that was my mom, I've only ever drank in the states, and I've been kicked out my share of bars here, so I'm sure i'd lose a tooth or two if i were to ever get to the old sod.
Oh, I dunno, I reckon there's a bigger danger of getting locked into bars in Ireland

Quote:
Originally Posted by Crossthread View Post
Oh, you aren't being ignored by any means! Over three thousand views so far! It may not be "Toxic Britney" but thats pretty good for a Battle Scooters thread. If you're REAL quiet... you can hear us breathing over your shoulder as you work.



Thanks for the encouragement
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Old 12-10-2011, 08:47 AM   #33
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Well, I got the underseat tank mount panel cleaned up and primed:



Leaving just the few plastic bits to be prepped. I made a start before work and discovered that the ugly yellow flakes off them easily without sanding.



The two side panels need slight repair. Tomorrow I will buy a fibreglass kit and do those before lightly scuffing the lot and sending all bodywork to the paint shop.

New colour scheme in mind now. It's a secret for now, O.K?

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Old 12-13-2011, 10:42 AM   #34
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And we are back

So, after being either lazy or busy over the last few days, depending on your perspective I got most of the paint off the plastics and readied them for repair.

I decided against fiberglass as I know a man who is a top plastic welder and he will sort them for a few dollars.



Mainly it's damage around where the panels bolt to the frame from being tightened too much.

I haven't settled on a paint shop yet so here's how the frame sits while it waits to be taken for paint.

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Old 12-13-2011, 10:48 AM   #35
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The Engine





Look at that powerplant!

And how a stripped kickstart shaft was remedied in the past



Have to get that off:



Bolt sheared, had to jemmy it off with a large spanner as a lever.



Here we have the gear selector shaft welded to the pedal



That's gonna be cut off as soon as my baby son is out of the house. Cannot make much noise in the spare room with a two month old around
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Old 12-13-2011, 10:55 AM   #36
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Turned it upside down. Yup, definitely should have washed this before starting the project



Polished exhaust manifold!



Undoing the peg/sidestand fitting:





Off.

Then I had to go to work

Good news is the engine ran when I stripped the bike down 13 months ago, has clean looking oil in it and may actually have a decent piston

Fun news is that I will be splitting the cases to replace gear selector shaft and kickstart shaft, possibly a gear of two, clutch and generally look at everything inside.

I have never done this before so things should get interesting!

It's 2am, I'm tired - so I am off home to my bed. Update tomorrow.
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Old 12-14-2011, 10:29 AM   #37
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So, today the carb came off first. Pretty fine, just a bit dirty.



Rocker cover next, looked o.k, but a bit gunky.



Camchain slack as shit.



The final bolt to get the head off was having none of it. I tried ll kinds of tricks to no avail. So I called the wife to get me my lumphammer and chisel.

Sorted.



In short, the cylinder head is toast as a large chunk of exhaust manifold was broken off a long time ago. How I didn't notice until I took it off is beyond me

Plus the valves were done in. Going to buy a new/secondhand head in the market tomorrow.

Here's how it looked:

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Old 12-14-2011, 10:36 AM   #38
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Piston has a lot of carbon. Also, notice how the loose camchain was wearing the engine casings



New piston now on shopping list. . .



Cylinder looks okay-ish


The baby was out of the house so I grabbed the angle grinder and chopped off the bodgy weld repaired gear selector pedal.




I'll need a no3 philips head and possibly an impact wrench to open the cases so one more thing to buy tomorrow.

More later,

J
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Old 12-15-2011, 07:36 AM   #39
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Although i admire your gumption, it does not seem like it's going to be very cost effective to rebuild an engine that has been subjected to kind of primitive 'fixes' and general abuse that this one has. Would be a lot easier and cheaper to purchase a used engine i would think. I know the satisfaction from bringing a 'beyond hope' project back from the dead, so i guess that's your motivation. Good luck.
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Old 12-15-2011, 09:17 AM   #40
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^

Yeah, I understand that this seems like that from your perspective.

Thing is, it's Cambodia

I could have had all the bodywork, the rims, the engine repair and loom done in a week by a local shop for somewhere between $120 and $150.

But I bought it as a little project to do myself in spare time and, having stripped and then left it for a year, have an urge to do it myself.

And it beats watching TV
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Old 12-15-2011, 09:30 AM   #41
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A little shopping trip.

I went to the market today. This particular market is a mecca of secondhand, cloned and aftermarket replacement parts for just about any type of scoot, but in particular Honda Cub/Chaly/Wave/Dream/MT type bikes.

If you can't find a bit for the above here it probably isn't in the country.

First I bought rims and spokes. I got a slightly wider rear rim than stock.



Then I began looking at some cylinder heads and realised that what I had thought was a chunk broken off the exhaust manifold is, in fact, standard design so the expanding pipe does not burst the cast manifold.

So I don't need a new cylinder head

I bought valves instead:



I picked up a full gasket set as I will be opening the cases:



When I went looking at pistons and cylinders I realised the cylinder in the bike was bored out to hell. Must have been 100cc or more.

Probably this bike pulled a tuk-tuk at some time.

So I bought a reconditioned cylinder and a new piston of unknown provenance.

Look at the difference in the bore!



I bought a No3 philips head but for an impact wrench too.

A prize to anybody who guesses how much my bill was

I b
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Old 12-15-2011, 09:35 AM   #42
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From past experience you will need an impact tool to get the case screws out or chew the screws up... but you know what your doing

Long time since I took on a job like your doing, keep up the good work, Im loving it
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Old 12-15-2011, 09:44 AM   #43
wanna bECO
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great! do the work yourself too... i understand the money thing...but tv sucks ur brain
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Just cuz my bike is shiny, doesn't mean that I'm a hiny

current stable

'94 Harley .... a blue one
'82 Honda passport
'87 Honda spacy 250
And an E Bike
85 spacy 250
81 passport (in pieces, many parts for sale)
The hit's just keep coming.. bought another 81 passport (11-28-09)

http://tiny.cc/ITgetsBETTER
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Old 12-15-2011, 10:21 AM   #44
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Originally Posted by ebbo View Post
From past experience you will need an impact tool to get the case screws out or chew the screws up... but you look like you know what your doing
Fixed

Yeah Beco, definitely doing it myself.

Off home now, bedtime.
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Old 12-17-2011, 09:33 AM   #45
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If it was cost effective I'd ship you a complete Passport bottom end. Got three in the shed gathering dust and one of them had only around 700 miles before it was cannibalized for parts. Sad.

This is an excellent thread about rebuilding one of these wonderful little bikes and will refer people to it. Thanks for sharing it with us.
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