QT 50

Coil case was cracked and needed a carb rebuild. started up first kick to my suprise, a testament to Yamaha's rock solid engineering. I love the QT50. 

00137 Honda 1980 C70 Passport / Cub

Phil's got my old Aermacchi, but I'm currently tuning his Honda Passport C70. Aka the Cub, it is the most common motorbike on the planet. This one was not idling at low revs, despite having the carb cleaned. On inspection, the bamboo points armature that is actuated by the cam on the flywheel had worn down to such a degree as to not open the points. This was resolved by simply adjusting the points. The oil centrifuge was de-sludged, and the gaskets replaced. Battery, though it holds a charge, probably doesn't have much life left to it. I'd have liked to take a look at the tappets, but the damn covers are seized to point where removing them would destroy the covers and possibly the threads on the head, so that's just not gonna happen. 

Now you see the engine.

Now you don't.

Sludge...wish I could get my guitar to sound like that looks.

 Pretty clean.

 Oil pump is fine.

 clean enough to pour oil on.

3rd world manufacturing

 Screwed into the case half...pretty ingenious design, so des ne?

On to the points! 

Points aren't moving. That there's your problem.

 Melted and corroded and generally non-conductive around the ignition and the electric starter circuits.

 Many hours later: 

Ahmed's Whizzer Rebuild

Ahmed had wrecked the shit out of his 60cc whizzer. I replaced the front end, rebuilt the front hub with a solid axle instead of quick release (!),  re-attached the clutch cam housing and added a lever with the correct amount of cable pull so the clutch would work, rebuilt the axles, tuned the carb, fixed the kill switch, replaced the broken throttle with an old Suzuki control, rebuilt the back hub so the brakes would work and the chain ring wouldn't rub on the brake arm, added a front brake (!),  trued the wheels and generally tightened everything to spec w/loctite. My final verdict after the test: whizzers are fun but totally dangerous. I gave Ahmed an extra helmet and told him he wasn't allowed to crash anymore.

Cute!

 

Leon's Peugeot 103 SP Rebuild

Treats sent Leon my way to fix his trusty ol' pug 103 SP....can you say basket case? We later found out it had been knocked over in a line of motorcycles and wrecked twice. This explained why the end of the crankshaft had broken off in the flywheel and the axle mount on the front fork was busted off. We replaced the front end of the bike. There were several vacuum leaks from worn seals and a Malossi intake that was not very well cast and had to be milled flat. Oh yeah, the bearings were shot, too. The bike had all the symptoms of coil failure, a very common pug problem (or any moped with original internal ignition coil). However, we had to get the flywheel off to replace the coil, which involved drilling out the bent & broken crankshaft after blowtorch & pullers did nothing except rip the threads off the flywheel (and my puller). Therefore, we had to replace the crank & flywheel....ie, total rebuild of the bottom end of the motor. No problem, except the first crank we got was out of spec. The threads on the variator side were .1 mil off and had to be re-tapped. When we tried to fire it up, it quickly became apparent that something was not right, and turns out the lobes were off by about a mil from being the right width for the case. Although it was properly shimmed & centered when assembled, it quickly wandered under the stress of running. It was replaced with a Gilardoni crank, which worked flawlessly. As the only available internal ignition coil was too small, CDI was the only option for electrics. This CDI was installed. No problem with the CDI, but the flywheel was junk: the glue holding the magnet to the housing didn't, and the timing mark flew off....Treats replaced the defective flywheel with this one and once installed, the bike ran like a champ. 

Yikes.

DIY woodruff key (no stock key, remember?)

Chinese

VS.

Gilardoni

Re-assembly!