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Thread: EN 125 overhaul

  1. #31
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    good onya with the project .
    a heads up. Those lil engines are fairly cold blooded anyway but stripping and cleaning out the carby completely will really help the idle issue.
    With the front forks I would clean up all the sharp edges of rust then try clear 2 pot epoxy one pit at a time. It needs to be about 1.0mm thick Once dried tou can sand it smooth with 1500 grit. used wet. you might get em working fine that way but not pretty so try a set of fork gaiters. They dont look strange at all once back together
    To see a life newly created.To watch it grow and prosper. Isn't that the greatest gift a human being can be given?

  2. #32
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    small update with the fork legs.

    (i think i had some other photos that needed posting but they seem to have got lost after the taupo trip )

    Anyway.

    Stuck on the clear epoxy, must say it looks a lot nicer right off the bat.

    Photobucket

    Then wet sanded it down with 400 grit, which was all i have right now

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    Seems to have worked ok. I like it anyway, I'll just stick some boots (gaiters?) ontop of them.


    On another note, I started stripping down the spring of the one shock i have apart (pending me getting more cable ties to get the other one done.) Discovered quite quickly however that its a little hard to get inside the spring with a wire wheel. So i'm also going to have to get a paint stripper of some description. Something that doesn't make springs brittle, which i'm told is a danger when applying those types of chemicals to springs.

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    Te audire no possum. Musa sapientum fixa est in aure.

  3. #33
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    Small amount of progress made, I got some emery paper and used that to sand the inside of the spring thus getting rid of the rust on the inside

    After half an hour of sanding I have a nice and shiny spring!
    Click image for larger version. 

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    Now to start on the other shock.
    Te audire no possum. Musa sapientum fixa est in aure.

  4. #34
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    Moar progress!

    Got the other shock off the bike and pulled it apart

    Setting preload to max and a zillion sticking cable-ties on it.

    Photobucket

    Backed off the preload wedged a spanner in there and twisted

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    And just like that it's off

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    Stripped the spring in the same manner as the other one and then covered them in primer

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    It was a little interesting spray painting a spring, the inside was just as hard putting stuff on as it was taking stuff off. So I ended up giving it multiple very very light mist coats to build it up as evenly as possible. Despite my efforts however the coat on the inside is not a thick as that on the outside and I doubt will be unless I dunk it in paint. However it is fully covered and ill give it another couple of coats tomorrow and that will do.


    As a time filler while I was waiting for the paint to dry I cleaned up the rest of the shock

    Photobucket
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    Te audire no possum. Musa sapientum fixa est in aure.

  5. #35
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    Alrighty got the rear shocks finished and back on
    progress pics for ya.

    This is my genuis rig to re-compress the springs seeing as I didn't have any of this "proper equipment"

    Photobucket

    Stuck a mass of cable ties on and did them up super tight

    Photobucket

    then pulled the spring off, stuck it back on the shock and wedged a spanner in there to tighten the top thingy off.

    Photobucket

    (getting it out was a pain though. Took me about half an hour)


    TA-DA! one assembled shock

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    What I did notice was that that paint wasn't fully hard yet and the cable ties left little marks on the springs. Too bad though i'm not pulling them apart again!

    Photobucket
    Te audire no possum. Musa sapientum fixa est in aure.

  6. #36
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    Looking good mate, nothing like attention to detail!
    Quote Originally Posted by Paul in NZ View Post
    Ha...Thats true but life is full horrible choices sometimes Merv. Then sometimes just plain stuff happens... and then some more stuff happens.....




    Alloy, stainless and Ti polishing.
    Bling your bike out!
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  7. #37
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    Quote Originally Posted by ducatilover View Post
    Looking good mate, nothing like attention to detail!
    makes all the difference eh?
    Te audire no possum. Musa sapientum fixa est in aure.

  8. #38
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    Quote Originally Posted by nathanwhite View Post
    makes all the difference eh?
    Too right, I can't stand people putting something together with shitty parts hanging out.
    I'm a bit mad though
    Quote Originally Posted by Paul in NZ View Post
    Ha...Thats true but life is full horrible choices sometimes Merv. Then sometimes just plain stuff happens... and then some more stuff happens.....




    Alloy, stainless and Ti polishing.
    Bling your bike out!
    PM me

  9. #39
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    ITS BAAACKK!!

    Righty, after a lengthy wait I finally have that little piece sorted that stalled the whole build.

    It was a little cappy type thing that held all the guts of the fork inside and well.... No forks = no front wheel = no engine = frame sitting in the garage waiting for something to happen.

    But anyway. Dad said he could rebuild the piece for free at the machine shop of the polytech he works at. Weeks later and nothing has happened so I'm chasing him up. Another coupla weeks and he finally has the piece, but it doesnt fit! Not his fault though, the pitch of the thread is something like 1.013mm. It's enough that the new piece (with a 1mm pitch) doesn't work.

    So a new plan is hatched.

    Instead of the cappy thing, put in a spacer and let the top cap hold the fork internals together.

    This is what we came up with:
    Left, spacer. Right, actual piece from other fork.
    Photobucket

    With that done, I charged ahead rebuilding the forks with nary a thought if I was doing it correctly

    Fork seal in
    Photobucket

    Dust cover on
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    Tube in and damper rod installed leads to a almost completed fork
    Photobucket

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    After some careful measuring, the spacer didn't quite go down as far as the cap would have, So I had to break the threadlock and stick an extra washer on
    Photobucket

    Then putting it in the fork, realized that the new washer was too large to fit past the internal thread

    So I had to spend half an hour or so carefully grinding and filing it down to size
    Photobucket

    But it all worked nicely in the end, so i'm very happy. The forks are assembled and ready to be chucked back on the bike. I (finally) found a service manual for the bike (en español.) I have fork boots coming, which is why they are not on the bike yet and this weekend I should have it almost completed!

    Photobucket



    I'm still not totally happy with the clear epoxy over the pitting in the tube. I think I may even just ge rid of it all and polish the whole thing with incrementally finer grades of steel wool and leave it with boots on.
    Te audire no possum. Musa sapientum fixa est in aure.

  10. #40
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    Mailman came!

    Boots will be on later this afternoon and forks will be on the bike also.

    Progress feels good!

    Click image for larger version. 

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    Te audire no possum. Musa sapientum fixa est in aure.

  11. #41
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    Good stuff dude, I love it when the mail man comes! (he's gonna be seeing me a lot over the next month)
    Quote Originally Posted by Paul in NZ View Post
    Ha...Thats true but life is full horrible choices sometimes Merv. Then sometimes just plain stuff happens... and then some more stuff happens.....




    Alloy, stainless and Ti polishing.
    Bling your bike out!
    PM me

  12. #42
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    Quote Originally Posted by ducatilover View Post
    Good stuff dude, I love it when the mail man comes! (he's gonna be seeing me a lot over the next month)
    How much more new stuff have you got to get?
    Te audire no possum. Musa sapientum fixa est in aure.

  13. #43
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    Quote Originally Posted by nathanwhite View Post
    How much more new stuff have you got to get?
    Not a heap.
    Fork rebuild kit.
    Oil filters.
    Lots of assorted fittings/lights etc, all been ordered.

    Few other bits and bobs
    Quote Originally Posted by Paul in NZ View Post
    Ha...Thats true but life is full horrible choices sometimes Merv. Then sometimes just plain stuff happens... and then some more stuff happens.....




    Alloy, stainless and Ti polishing.
    Bling your bike out!
    PM me

  14. #44
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    Small problem that I anticipated was the boots not fitting quite correctly.

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    Nothing much about this bike is usual it seems, always odd sizes and shapes. Makes it a little hard to get parts and stuff In this case it the fork stanchions were 30mm and the top of the bottom fork thingys were 50mm. The boots I got were 32mm and 52mm respectively.

    However that particular problem was easily solved with cable ties, and then it was onto putting the forks back on the bike!

    Regreased the speedo unit. I didn't how much was actually needed, so I just put it every where
    Photobucket



    Then it was line everything up and stick the axle in and

    VOILA



    oh wait, no not just yet.....

    Had to clean up the bolts holding the brake rotor in (and show the obligatory pic of before/after)
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    The pictures don't really do it justice, they come out really nice and shiny.


    When that was all together,

    VOILA

    Photobucket

    rolling chassis. Ready for engine in and general rebuild tomorrow.
    Te audire no possum. Musa sapientum fixa est in aure.

  15. #45
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    You should remove that key Dougle...it has the potential of being snapped off in the barrel all exposed like that...
    But...looking good, you have much to be proud of here.

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