New parts bought whilst on hols Aug/Sept 2012 from Scooter
Restorations. Dealt with Jeff Johnson mainly.
They sent wrong fly-screen with a round headlamp hole. OK
for LI models and series 2, not SX Doh!
Sat 22 Sept 2012
Went for a ride down the Alektora Rd and lost RH side panel off.
It is seriously scraped & scratched.
Sun 23 Sept
I’ve now fixed the seized side panel handle which led to the
errant panel yesterday. Why didn’t I do it weeks ago? Just as well I've got a new pair of SX style panels to go on.
Friday 28 September
Fitted side panels with new handles, seem ok although the rh
one is a bit awkward to remove.
Sat 20 October
Drilled new side panels and leg-shields for badges
23 October
Second batch of spares along with the correct fly-screen
arrive from Scooter Restorations, it’s been a long wait, must have come by donkey.
A lame donkey with only three legs.
New air filter hose fits a treat along with air filter end
plate. Must get on with fitting new ignition switch and sorting out the lights
etc
27 Oct
Fitted new horn, headlamp and ignition switch. Everything
working, one long brown wire left from ign s/w to headlamp connector block. No
idea what it’s for.
2 November
Made a scooter work stand, built and sprayed in one day,
(apart from cutting some of the steel yesterday). Hard work but it’s done now,
fits in the shed perfect
3 November
Moulded new floor runners to fit leg shields. Whoops, I’ve
ordered two lots of floor runners, must sell the spares on eBay.
Removed front mudguard, rear foot boards. Removed brake pedal, then leg shields.
Removed silencer and exhaust manifold and carb then cylinder
cowling.
Found suspension strut easy to remove, no seizure. Might
whip out the engine tomorrow.
5 Nov
Spoke to spray shop in Pafos, no speaky english, I think he got the message in the
end. Spoke to Yannis at Everblast, says they can soda blast the engine and
plastic bead blast any other parts required, sweet!!
6 Nov
All cables out, headstock off, engine out. Thanks to
Sheena for lifting the frame off the engine
Lots of cleaning up to do.
8 Nov
Rear light mounting removed, side panel spring
removed, rear mudguard removed, brake light sw removed, stand removed.
All oily deposits cleaned with thinner and wht spirit.
Metal bashing carried out to frame cross member, must
remember to weld up stand mounting holes which are cracked, also holes below
rear number plate. Cancel the last, they’re supposed to be there.
10 Nov
Welding done to stand mounting bolt holes, further
metal bashing to get cross members something like straight. Cross members
re-welded. At least one of them seems to have been replaced and welded on in
the wrong position
Stand spring and choke cable guide de-rusted
11 Nov
Flywheel
cowling & dustcap removed, cleaned, dustcap refitted.
Start engine degrease. Tape & blank exhaust, inlet and
flywheel prior to blasting.
There's things growing under that engine!
Both wheels removed from hubs. Rear hub and brake shoes
removed.
13 Nov
More degreasing & cleaning engine. Drilled out
gear cable trunion that was seized
14 Nov
Removed
cleaned and re-assembled and greased brake shoe cam shaft . more engine
cleaning. Drained oil.
Its a mucky filthy job 44 years of muck and oil stuck to
the crankcase. I got a lump of this crap in my eye laced with petrol which i
was using as a cleaning agent (not for cleaning my eye that is). Thank god i found it before i had to ask sheena
to have a look. Last time she nearly poked my eye out.
Another two sessions
should see it clean. Everblast yannis will not answer his blasted phone.
27th Nov
Yannis from Everblast has been ill
apparently thats why he wont answer his phone.
Last clean off of the engine today, ready for soda blasting.
Looks like it will get done along with the rest of it in January.
29 Nov
Order placed
for next batch of spares. More cleaning to cowls etc
30 Nov
Last of oil and crud cleaned off cowls, silencer,
etc.
Got cylinder cowl braised up by George Anathasiou. Lo & behold, he’s
got a shot blast cabinet which he says I can use for components. See him in
January.
31 Dec
Back from uk night before last (Saturday 29) lumbered
back with sports direct bag full of lambo spares, rear carrier, new wheels,
rear hub, set of cables and shit loads of small bits, nice.
Really looking
forward to starting the dry rebuild. After various social gatherings I suppose,
oh and maybe some proper work thrown in at some point.
10 Jan 2013
No work this week off with pneumonia
14 Jan
It has now become obvious, the whole thing needs re-building with the new parts before any paintwork prep needs to start
Made a start on the dry rebuild.
Restored stand to original spec by cutting off assorted nuts
that had been welded on to improve it due to stop brkts being bent out of
position and one leg being a bit short apparently? Cleaned up and bashed the
stand brkts back into place. Fitted stand and splash guard.
Replaced front & rear brake shoes with new ones. Fitted
new rear hub. Refitted front and rear wheels. Managed to lose circlip from
front brake drum operating lever. It pinged off at speed in an unknown
direction.
Threw engine back in place. That’s enough for today, I need
a hot bath.
15 Jan
Found missing circlip whoop whoop, fitted it. Went to
Georges garage to ask where I can get copper grease, he will order me a tin.
Fitted engine cowling and tried to fit flywheel cowl.
Threads gone in all but one position, nightmare. Looks like I’ll have to go up
to 10mm and re-tap thread. If that doesn’t work, it will have to be ally.
Welded, re-drilled and tapped at 8mm. Flywheel cowl about knackered, needs
welding up or a new one.
Fitted rear mudguard, very difficult with the engine in
place, note to self, do it first next time.
Installed new rear light unit.
16 Jan
Took engine back out for access to knackered threads.
Borrowed a 6mm tap from Rick Kendal and cut oversize threads to top, three o
clock and bottom positions. Lo and behold, it worked, and the cowl is fitted
firmly in place using 10mm bolts. Now just to take it off again and get the
loose screw out that I dropped inside L Did that.
Engine is now ready to re-fit. Maybe I’ll fit the regulator,
coil and wiring loom first.
18 Jan
Coil fitted along with regulator which I’ve moved
from the side strut up onto the frame opposite the coil.
Fitted and removed the wiring harness a few times, couldn’t
decide on the routing. Had to replace the bullet connectors on the rear light
wires for spades. After speaking to Alun I decided to solder and crimp them. The spades I have
are a size too big so squeezed them smaller to fit. Didn’t work well as the new
rear lamp fitting spade connectors are piss weak. Made new earth lead for rear
lamp. Eventually done but what a pain in the arse. The brake lamp/rear lamp
wires may need changing round later.
All together a shitty day at the scooter. Won’t get much
more done before the kids arrive Sunday 20th.
26 Jan
Murray helping. Put engine back in. Re-connected wiring including brake lamp
switch. Murray
fitted the switch, the tail light earth and the new back brake cable. Looks
like the headstock will need to go on next.
2 March 2013
Missed a few blog updates but headstock is back on.
New gear change lever although the inner plastic bearing won't fit. The new casting is thicker. It seems ok
without it. Throttle operating arm and cable locator is fitted. Cables next.
Speedo taken apart as plastic casing is melted. Adapted
metal casing and fitted it. This should negate the need for an earth wire. Bit
of a faff, will need a new speedo seal and 3 x washers next rebuild.
New wheels, tyres and tubes x 2 built up and fitted. That’s
it for today.
Sun 3 March 2013
Fitted carb.
Installed throttle, clutch, front brake and gear operating
cables. Once I’d stopped trying to fit the throttle cable to the front brake
lever, it went very well. Need the engine running to check clutch, gears etc.
Choke cable next
4 March
Choke cable fitted, bit loose at carb end though
although the choke seems too work ok
Fuel tank fitted, easier than I thought.
Stuck some oil and petrol in but flywheel scraping badly on
the cowling. Cowling contours re-defined (smacked with a hammer) and now
clearing. Re-fitted said cowl but no start. Loads of spark. Fuel appears to be
pissing out of the carb somewhere. Carb removed ready for stripping down.
Bollocks
5 March 2013
Removed float chamber, waggled float around,
re-assembled and fitted carb.
Wahey, it started (after a lot of kicking over)
Various electrical problems such as brake light, horn etc.
Headlamp works and dips ok though.
Messed about with the electrics, loose conex to rear lamp.
Took it for a ride round the car park, all gears select but
back brake is rubbish, front not much better
At least she runs.
9 March
Had a look at the electrics with Alun Jones. The
connectors are so poor in the headlamp bulb holder, I’ve decided to cut them
back and just make common connections into a chocolate block.
ANYTHING TYPED IN RED IS FOR ME TO REMEMBER ON NEXT REBUILD
10 Mar. 13 fitted replacement air box (in the box of spares
I got from Steve) & air scoop. Fitted new side panel buffers. Tidied up
wiring at the back end. Re-route loom to back light
down rhs next time. Got tool box ready to fit, rubbers need heating up
so will do this later
11 Mar. 13
Them toolbox rubbers are a pig to fit. Will leave
them till final assembly so toolbox fitted minus rubbers. NB do not fit air
filter box before the toolbox, air box had to come back out. Whoops, dropped the
bottom air box nut into the engine. Great, carburettor and flywheel cowling have to come off to get
the blasted nut out.
All back together NB do not fit
carburettor till last thing on next rebuild. I’ve lost count of the times it
has been on and off.
Added a bit of tension to gear operating cables also clutch
cable. NB do not fit clutch cable till gears are
adjusted as it gets in the way of the spanner on the cable adjuster.
One pace forward, two back today.
Have bought choc blocks for wiring.
14 Mar. 13 C
lutch and front brake pivot bolts tightened up.
Took the plunge and snipped off all bullet connectors apart
from blue, red (headlamp wires) and white (earth). Tinned stripped ends with
solder and choc blocked them together as required. All works apart from rear
light which doesn’t seem to have a power supply (inc. Brake lamp). Will sort
out next time using wiring diagrams.
16 Mar. 13
Rear lamp
was intermittent due to poor connection on the crappy new (Indian made) back
light unit. Sorted it now.
All electrics now working including the horn which sounds
like a frog with laryngitis. Turns out the festoon lamp under the headlamp bulb
is just for a parking light. No battery on this scooter so it’s surplus to
requirements.
Started her up and had a spin round the car park, no
noticeable rear brake. Needs re-rigging. Operating arm was to far
anti-clockwise, moved it round, re-adjusted cable at the front end. Seems
better but the shoes need bedding in.
There appears to be quite a bit of backlash in the gear cables,
they also need re-rigging.
New seat and rear carrier thrown on temporarily. Lots of
vibration through carrier, needs rubber pads where
drop down part rests on t’other bit.
That's enough today Australia F1 qually to watch, then England v Wales
Six Nations match
18 March
Don't ask about the rugby.
Rear brake re-rigged. New speedo cable fitted.
Knurled connexion to speedo wrong size salvaged the old one which fits ok.
Bottom connexion rubber boot is crap it’s as soft as tissue paper. Will maybe fit old white one on final rebuild? Disconnected
festoon bulb live feed. Headstock cover re-fitted.
Time for another run out. Back brake better but still has a
high spot where it binds. It might bed in with use.
Will check wear pattern on strip down. Gears still sloppy, trunnion and
operation arm look worn out, will get replacement,
no point in adjusting cables further.
Clutch adjusted almost to biting point, may need backing off a tad? Speedo is loose inside casing, it’s jiggling about, fix
it next time.
Apart from the above, everything works electrically. She
started first kick so no point in fiddling with the mixture etc.
28 March
Side panel rear attachment and number plate fitted.
Side panels fit, no rubbers fitted at this point.
30 March
Leg shields, floor panels horn casting and front mudguard
fitted. Seals for horn casting tool box side panels bridge piece all to be
fitted on final assy.
Flyscreen and mirror trial fit next
13 April
Very busy with work so little progress recently.
Flyscreen and mirrors fitted (the mirrors are useless, they won't stay put and I can't see behind when they do) Apart from that, they are fine.
Had a few test runs, everything seems to work, although the brakes seem fairly poor even after adjustment. I'll have to save up for a disc brake conversion.
Went up the big hill above Aphrodites Rock, determined to get to that gazebo on the top. Horrendous rocky track but got there in the end. No photos as I forgot my phone.
Got home and half the nuts and bolts had come loose. Must invest in some Loctite for the final build
OK, dry rebuild declared finished.
Time to strip it down again.
.JPG)
