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.

27^th 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 20^th.

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.