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I did it again... Bought a baby blade to rebuild...

Discussion in 'Biker's Cafe' started by Malt_Vinegar, Jun 10, 2019.

  1. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    Things have stalled a little bit for a while. I am building a concrete pad/shed in the garden on my tod, which is soaking up any free time I have right now. However, this top yoke arrived to replace my screwed up one:

    [​IMG]

    [​IMG]


    Looking pretty mucky, but its all there, and looks in good shape.

    Dunked it into some citric acid for a few hours, attacked with a toothbrush:

    [​IMG]

    Came out looking like this:

    [​IMG]

    [​IMG]

    Looking a little bit cleaner, now for some sanding/polishing:

    [​IMG]

    Not perfect yet, but should look a little nicer on the bike now!
     
  2. Felix

    Mobster

    Joined: Jan 25, 2003

    Posts: 2,702

    You must spend half your time on ebay finding new parts!
     
  3. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    Alwyas have my eyes open for a bargain :) Shed slab is down and curing, hoping to build the outside of the shed this weekend, so will be able to get working on the bike again soon, and swap out the motor.
     
  4. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    The bike shed is almost done, and i had a few minutes to spare, so decided to work on a couple of small things that were bothering me..

    Swapping this over:

    [​IMG]

    This was also bugging me:

    [​IMG]

    Stuck the cap into some faithful Citric Acid, being careful not to get too much on any rubber parts:

    [​IMG]

    Couple of minutes:

    [​IMG]

    Gave it a quick rub down, and put it back in for another few mins:

    [​IMG]

    Not perfect, but MUCH better :D

    Threw it all together again:

    [​IMG]

    Looking forward to getting it into the shed this weekend, and might be able to get the old engine out, and perhaps the new one in :D

    Also, I need to work out the cable arrangements, as I can't quite make it look OEM.
     
  5. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    Shed was delayed as I am waiting for lino.. Should be here in early Jan..
    However, I did decide to remove the old engine this evening in the garage and it is now OUT.
    Yes!! Was a bit of a faff, but not too horrible.
    Ran out of time to go any further tonight, but I might have the new engine in some time over the next two days before I go away to visit relatives.
    Otherwise, it will be in early Jan.
    Pics to follow
     
  6. The Deuce

    Wise Guy

    Joined: Oct 18, 2002

    Posts: 1,933

    Location: In the sticks

    enjoying this build, had both a NC24(in Rothman's) and 23(in grey&gold) back in the day, great fun bikes
     
  7. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    Great to hear, lets hope this turns out to be as fun!

    So, my late night engine replacement antics kicked off as I stated above.

    So, this was the old block in place:
    [​IMG]

    Lets see if we can whip it out:
    [​IMG]
    Long story short, yes, I can. Took about 2 hours, mainly because I was faffing a bit, and working in limited space!

    Big empty gaps!!

    [​IMG]

    [​IMG]

    New tested block ready to go in:
    [​IMG]

    I then also decided to start swapping over the drive gubbins to the newer wheels. I think I want to go white on these original wheels, but I can do this at leisure whist the new wheels let me ride!

    [​IMG]

    Cleaning up the disc whilst I have it in bits. Will likely need replacing soon anyway, but I want to have a go painting the inner tab parts to see how it holds up in use :)

    [​IMG]

    That's where I am up to, so hopefully may get the new engine back in tonight before I go away till the new year :)
     
    Last edited: Dec 26, 2019
  8. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    Disc cleaned up and masked:
    [​IMG]

    With VHT silver:

    [​IMG]

    [​IMG]

    Being baked:

    [​IMG]

    Looking kinda sorry, with new engine ready to go in:

    [​IMG]

    Disc back in place on the new wheel:

    [​IMG]

    Ready to go on:

    [​IMG]

    Moved over a couple of cables, and bits from old to new:

    [​IMG]

    Annnnd its in!

    [​IMG]

    [​IMG]
    Went in much easier than I thought, as I figured out a better way to jack it up on my own to keep it level.

    Got to replace the oil filter, do a quick oil change, refit some coolant hoses/etc. There is also the carb rubbers/and a few odd bits.

    Then its just plugging it all back in and seeing if it will start :D

    However, I am not around for a week, so it will have to wait till the new year :(
     
  9. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    Carb rubbers were tough to remove on the old engine (new ones ordered), and the clamps were looking very sorry for themselves:
    [​IMG]

    Take to bits, and dunk in the usual:

    [​IMG]

    Looking a bit better now:
    [​IMG]

    [​IMG]

    [​IMG]

    Coolant pipes also looking funky:
    [​IMG]

    [​IMG]

    Dunked:
    [​IMG]

    Out:
    [​IMG]

    [​IMG]


    New rear wheel on:
    [​IMG]

    New coolant pipe o-rings vs the old:

    [​IMG]

    Tried my luck on some random fuel filler bolts:

    [​IMG]

    Not all of them fit, but some do, and fills the gaps in the ones I did not have :D
     
  10. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    I threw the old girl together today, and took her for an MOT... I was not really expecting her to pass, but I booked her in, at the local garage is a racing bike prep place. They actually have said before, if you are not sure, bring it down for an MOT as its much cheaper than paying us by the hour to look it over!

    The ride down to the garage...Firstly, it's a very sprightly little bike, even in its freshly put back together form. I only had about 2 miles to ride her there but I really enjoyed it. However, IT WAS VERY LOUD!! (More to come on this later!) Brakes need a bit of tweaking (more to come on this too) but over all, it held up, and i went through all the gears, the lever needs to be adjusted, its way too high at the moment which makes up-changes difficult.

    When i got there, i told the guy it was basically very loud, and apologised, and he found a little (actually MASSIVE) hidden between the collectors in the exhaust. He said it would be an immediate fail, but I asked him to go through it anyway so I can get it checked out.

    About an hour later, the fail sheet arrived, and it was nasty

    Date Result Details
    25/01/2020 13:48 Fail
    Mileage:
    10,211 kilometres
    Refusal Notices
    • Nearside front brake disc fractured (1.1.14 (a) (ii)) - Dangerous
    • Rear brake pad(s) less than 1.0 mm thick (1.1.13 (a)) - Dangerous
    • Rear wheel spindle or securing nut(s) so insecure that wheel security or steering control is adversely affected (5.2.1 (c) (ii)) - Dangerous
    • Exhaust has a major leak of exhaust gases (6.1.2 (a)) - Major
    • Exhaust noise is clearly in excess of that emitted by a similar motorcycle fitted with a standard silencer in average condition (8.1.1 (a)) - Major
    • Handlebar grip missing (2.2.1 (d) (i)) - Major
    • Front brake master cylinder insecure (1.1.10 (c)) - Major
    • Front wheel bearing has excessive play (5.1.3 (a) (i)) - Major
    • Rear brake caliper insecure (1.1.16 (c) (i)) - Major
    Advisory Notices
    • Front wheel has a slightly distorted bead rim (5.2.2 (c) (i))
    So, lets knock these all down:
    Nearside front brake disc fractured (1.1.14 (a) (ii)) - Dangerous
    New discs have been ordered, along with the rear, seeing as they came as a set, and will match designs, which is nice :D

    Rear brake pad(s) less than 1.0 mm thick (1.1.13 (a)) - Dangerous
    Again, ordered a set if rears to turn up sharpish, and then got the fronts with a spare set of rears (they were a nice price, and a bundle with slower postage) for later in Feb.

    Rear wheel spindle or securing nut(s) so insecure that wheel security or steering control is adversely affected (5.2.1 (c) (ii)) - Dangerous
    Errrm, little oopsie from me here, I missed a spacer on the rear axle, and this meant the rear wheel could not be tightened fully!
    So, checked the old wheel, located the missing bit, removed the wheel on the bike, and swapped it over.. Job done :D

    This negated the following point too:
    Rear brake caliper insecure (1.1.16 (c) (i)) - Major
    Nice and secure now the spacer is in place!

    Exhaust has a major leak of exhaust gases (6.1.2 (a)) - Major
    Exhaust noise is clearly in excess of that emitted by a similar motorcycle fitted with a standard silencer in average condition (8.1.1 (a)) - Major

    Ordered myself a shiney "Delkevic" downpipes in stainless steel - should be here in a few days

    Handlebar grip missing (2.2.1 (d) (i)) - Major
    I had no idea this was a major, will get them fitted before the retest!

    Front brake master cylinder insecure (1.1.10 (c)) - Major
    Looks like I had not quite torqued this up fully, we actually nipped it up there and then, should not be on the sheet!

    Front wheel bearing has excessive play (5.1.3 (a) (i)) - Major
    Ordered a replacement set for a very reasonable price!

    The only advisory:
    Front wheel has a slightly distorted bead rim (5.2.2 (c) (i))
    I went down with the original front wheel on, so may be able to knock down the wheel bearing and bead issue just by swapping it over :)

    A little pic of it whilst it was being looked over (did not put the full fairings on again yet)
    [​IMG]
     
  11. MowyTone

    Mobster

    Joined: May 4, 2009

    Posts: 3,366

    Location: Southampton

    All good progress. At least there's no shocks as a result of the MOT
     
  12. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    Few little bits done for the MOT re-test this AM :)

    Found some CG125 fairing rubbers that seemed to fit my tank, which makes the fairings fit a little more nicely!

    [​IMG]

    Wait, what's in this big box :D

    [​IMG]


    Niiiiceeee, should work a little better, and be a little less holey than the original!

    [​IMG]

    Lets throw it on! It went on with a little fiddling, some of the pipes did not quite line up, and needed a bit of persuasion to get into place, but I am told that's not uncommon with this sort of thing:

    [​IMG]

    [​IMG]

    Only problem is....

    [​IMG]

    [​IMG]

    It seems the end can on the original pipe will no longer fit. The original exhaust had had an extra flange welded onto it to take a non-standard pipe.

    So, that will not do!!

    But wait, this looks a little nicer!!

    [​IMG]

    Got this bargain pipe for it, little longer than the old one, and looks a little more factory imo!


    Brakes were up next!

    [​IMG]

    You may notice the front pads are missing, just waiting on them to come in from China (they were not a problem on the MOT anyway). However, this little lot was not cheap, but should look a little nicer than the original, and hopefully give some decent performance.

    [​IMG]

    [​IMG]

    Some of you may notice that the front wheel has changed, back to an original NC23 wheel, which should take care of the knackered front bearing issue.

    I was not happy with the front brake lever/master cylinder. It seemed to have a pinhole leak somewhere which was annoying me. So, I moved to a new lever, and had to work out where to mount the fill pot. The standard bracket would not work, as it kept fouling the fairing.. So, i whipped up a small bracket from some scrap lying about:

    [​IMG]

    [​IMG]

    Tucked away, and no longer fouling the frame/fairing anywhere :)

    Rear pads/pin were up next:
    [​IMG]

    I put new caliper pin dust covers on all round too:

    [​IMG]

    Rear disc, as it came with the fronts in the kit!
    [​IMG]


    Rear end back together:
    [​IMG]

    I had bought a fuel tap lever from a later bike, as I could not find one for this type, but it was too long, and was sticking out where my knees would be, and would get knocked about. It sort of fitted, but the square indent on the end was way too big, so I used a bit of whitemorph in the end, to get the shape right, and tested it. Worked fine, but was still way too long. So I cut out the middle section, and re-glued it back together:

    [​IMG]

    The whitemorph:
    [​IMG]

    Re-melting the whitemorph for final fitment/moulding:

    [​IMG]

    Ready to go:

    [​IMG]

    Much neater!!

    [​IMG]

    Not going to get poked here by accident anymore!

    [​IMG]

    Hopefully back down for the MOT re-test today :D
     
  13. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    She is legal..... :D:D:D:D:D
     
  14. The Deuce

    Wise Guy

    Joined: Oct 18, 2002

    Posts: 1,933

    Location: In the sticks

    excellent, looking forward to more updates
     
  15. Malt_Vinegar

    Don

    Joined: Oct 20, 2002

    Posts: 15,174

    Location: In a house

    [​IMG]

    [​IMG]

    It's fun! needs some work on the setup/carbs, but I might just pay the local dyno place to give it a once over. It revs so high, and sounds amazing. Not taken the bung out yet, but I will get around to it soon :D
     
  16. BongoHunter

    Wise Guy

    Joined: Apr 14, 2014

    Posts: 1,761

    Lovely looking machine - great thread!
     
  17. Shimmy

    Man of Honour

    Joined: May 30, 2007

    Posts: 5,568

    Location: St A

    Great work that fella, first legal ride out must have felt so rewarding!
     
  18. Yaayuh!

    Capodecina

    Joined: Nov 5, 2010

    Posts: 19,912

    AWESOME.
     
  19. MowyTone

    Mobster

    Joined: May 4, 2009

    Posts: 3,366

    Location: Southampton

    Noice
     
  20. bloodiedathame

    Sgarrista

    Joined: May 11, 2007

    Posts: 7,721

    Location: Surrey

    You're lucky you didn't die on the way to the test! :D