Kimjon

Normally the valve cover vents into the air filter and any dirty oily blow by is fed directly back into the motor and burnt in there. I removed the stock airbox, so had to come up with a solution. Option A: do nothing, vent to atmosphere. But end up with oil everywhere. Option B: run a line, dump to ground like an early motorbike would. Fine on the road, not so cool on your own nice concrete driveway. Option C: run a catch can like a race car would. So in true style I elected for the most complicated solution (Option C). And rather than spending around $70 to buy one, i further complicated it by making my own scaled down version on the lathe. Bracket: Mounted loosely in position: It's loosely bolted there for now, and missing the sight tube (4mm clear pneumatic tube, will allow visual of oil level in the catch can)...but looks the part.

The throttle linkages are a mess on these. They are reliant on the governor and when that's removed they flop about. I got it functional, but it looked untidy. So I cut it up and reshaped it: Before (functional...but pugly) And after (still ugly, but better) I'll paint it and see if it "disappears". If not and it still annoys me, I'll mill one up out of alloy.

With some of the mods I'm doing, more air will be entering the motor. I geeked out and read up as much internet information as I could find on the topic. Solution, drill the main jet out from a factory 0.72mm up to 0.94mm. Actually 0.90mm was the recommended...but I didn't have a drill bit that size, so 0.94mm it is. I guess if it runs super rich, I'll look at swapping out the carb for a mikuni or similar. But I'll cross that bridge if I need to later on.

And dry fitted to test...happy for now, will port match after welding on header pipe.

And exhaust flange (hehe...flange )

Got a bit more done after work yesterday. Motor mount:

Started tearing down the motor. I'm waiting on eBay parts...probably won't see them until after Christmas? But may as well get started now anyway.

Clutch dry fitting on motor to figure out engine mounting

Rear sprocket

Upcycling at its best

Kind of forgot about this project. Started on making a motor. Using a Honda clone, I'll do the usual modifications to make it faster...plus add my own flavour to it as well. Engine mounts, clutch, chain and sprockets...plus the exhaust up next. But all in good time...

Doing a fantastic job.

Motor does just under 9000rpm...cheap Chinese rev counter was wrong. I put reflective tape on flywheel and clocked it with a laser. Slightly relieved, as the numbers just weren't adding up before.

Hi Pete Glad you like it, as I felt bad cutting it up to begin with, but I had a vision (and an angle grinder plus welder ). I've had it up to 70kph, but it hits the wall about there and won't go any faster. The carb is running super rich, and I'm going to have to double check revs, but my tacho says I'm only getting 3500 under load (its possible im on wrong setting, but don't think so???, well that's if the Chinese to English translation is correct in the manual???). My gearing is much taller than yours was, so I think it's a combination of high gears and bad tuning...but fuck it, going to run it like that and worry about fixing issues another day. Cheers Kim

That's awesome! I have an old parts washer with no pump...may have to copy (blatantly steal) your ideas.

One last photo, in all its sexiness Kj

I've had it up and down the road a few times now...goes good! Still has more in it, as the tune isn't perfect yet (far from) and a bigger carburetor would be ideal...but I'm smiling :-). I even had time to tie and solder the spokes (a bit rough) And make a safety guard for the cvt driven pulley, just in case it brakes free of the motor. That should do it for now.

Bit of a late night, but things are moving in the right direction:

Exhausts tidied up. Side by side before and after:

Got the paint on last night. I figure I may as well experiment with it, so here it is: Yip, clear. The sexy bear metal looks so good (well to me anyway), I thought why hide it under coloured paint? I used por15 and although not uv resistant, realistically its not going to see much time outside...so it should be fine? This is part of my experimenting, as I'm curious in how long it will last? Worst case, I'll sandblast it off and paint it boring black if the clear doesn't work. Assembly in the weekend.

Frame back to bare metal

Looked at the calender and had one of those "oh fuck!" realisations that I'm quickly running out of time. I squeezed in the finishing touches (totally untested) and started stripping it down. Finished the hard to reach welds that were underneath stuff: Then stripped the frame I'm about to have a cup of tea like they would in "Project Binky" then attack the frame with a wire wheel. Hopefully get some kind off paint on it this week and put it back together next weekend?

Yeah man, nailed it!

Seat moved back a few inches And that's it for now.

Hubs...this was painful! I cut the spline centre out of the original hubs, then grafted it into some other hubs that didn't fit. Then machined them so they do fit. Yes, that's right...painful!