Ok, now the net is back at our place, i can update a little. Bike is running, thanks Az for uploading the video. The gopro has a strange way of recording sound. If we were making rat bikes, i could pretty much leave it as is and win the comp, but i don't think my fuel tank design will cut it for the modif off concept. A few more things to test, new clutch and gear selectors need checking especially. While the other two are off having seats made, it seem i am going slow, but at least i know them mechanicals of the bike will be spot on.
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A Pulpy Mango, some messed up wires, some dogs and of course a few Bintang besar got her started ... I actually don't even know her name ... I know Tom definitely put in some pumped up kicks to turn her over, check the link :) az xo There is a spanner in the works... Hit a small hurdle with the carb, seems to have developed a mystery problem since being disconnected and the slider is sticking at wide open throttle. That's a pretty dangerous problem! When i find some time, ill get on to it and try and run the bike. That is looking like Saturday at this stage...
Polished engine covers came back from 88Chrome. They did a great job restoring them, and even chrome plated the clutch throwout lever. Even though this was the most expensive process of building this bike yet, i would recommend them for sure. The finished covers let me complete the engine assembly, adjusting valves and giving the new internals their first drink of oil. While Llana was at work, i managed to turn the living area into a makeshift bengkel, and got the engine fitted in the frame with new stainless bolts. Looking good, engine compression feels good and the engine seems to turn over smoothly. A bit of wiring and i might even brave a test
Ok, like everything, life is not easy dabbling with old engines. First task of the day was to make a tool to suit the peg bolt for the centrifugal oil filter nut. I used a steering column from the original CG forks, a grinder and a pipe spanner. Crude, but effective. I seemed to spend a lot of time with grinders and hammers for what could have been an easy socket job. Next "easy" job was changing over the clutch housing and clutch plates as the original housing was worn and had too much play on the main shaft. Another "Honda Surprise", seems they use a pressed pin system to keep the ring gear attached, rather than bolts. Grinder again, off to buy some pins and some more time with the hammers. A solid hour job to get the new pins in. No fun, but it would be easier if i had to do it again. Once the clutch was done, and some bearings replaced, it was time to reassemble. A few more hurdles, as i am using custom cylinders and housings, the original gaskets of course needed modification. New piston fitted, gaskets in, head and casing seem to match up together well. I wish i had taken a before and after photo of the carb, i have never seen a dirtier fuel system than this. So much brown poo rusty fuel and dirt came out. Spotless now. All i need now are the casings back from polishing before fitting back to the bike
So, did some more engine work today. Took some covers to be polished at 88 Chrome. Thanks to Yudhi for helping with the price. :) Clutch housing was showing some wobble on inspection, and i thought best to replace it. This involved a ride through 2 feet of water for a run to Tiga Berlian for spare parts. The KLX did a good job of getting me through where others were stuck. My shoes are now in a poor state though. Found a new rumah kopling (clutch housing) and genuine Honda friction plates. Just have to work out how to remove the Honda CG centrifugal oil filter with a special 'key socket'.. Thanks Honda, i don't have access to "special tool m341-7899". Ill have to make my own i think. Engine now should be pretty sound, new seals, valves, piston, bored case, clutch and transmission bearings. Should be solid as a rock.
Ok, in order to get ahead of the "modern engine" boys, i am doing a bore up, polishing the ports and a new set of valves. This should up the horsepower and give them a little grief in the modif off battle. Honed out the crankcase, and bored the cyl to 63.5mm to suit a standard tiger piston. See the difference between the original size and the new one. New set of valves and oil seals. Should be a bit nicer to ride. Looking to polish the engine before reassembly.
Metal work on tank, seat pan and rear section look good. Front stubby guard fits well. All i need now is a dry day, so i can go out and do some more work with the grinder on the frame before a test assembly.
Ok, time to get one up on the competitors.. I know they wont do this to their own bikes. Tore down engine today, the old pushrod system is quite easy, and solid as an anvil. Boring out the cylinder to suit a 63mm piston from a Honda Tiger 200cc. The Honda CG will be getting a sneaky 40% or more engine displacement increase. The Head is off to another place to lap the valves and polish the ports to free flow the fuel and exhaust. Ill give the carb an overhaul while they are at it, so that i can quickly re-jet when the engine is running again. Intended turn around time... Monday! Cost.. Less than 40 dollars for 40% increase. Money well spent, unless i get my measurements wrong and blow it up... :) My competitor with his shiny "new" mid 90's enginge. Smooth sailing while i toil away with 30 year old gear. I am sure he will be saying.... "its not about how big it is fairly soon" Some nice carbon deposits there. Maybe 30 years worth. Head is off for a little spruce up, and reseat the valves. Cheaper than doing it myself, as i don't have a valve compression tool for removal here. Its cheaper than buying one.
More posts to come soon when engine is on its way back together with shiny new stainless bolts. Peace out. Thankyou for choosing to replace some of the engine bolts with cheap, low tensile mild steel self destructing bolts. I hope you spent the 50c you saved wisely. Rest assured, the 2 hours i spent with an impact driver, hammer, grinder and rotary tool to remove the destructo bolts was good time to plot my revenge against you. I wish the wrath of 1000 highly skilled ninjas upon you..
Much love... Tom. |
Honda CG
So, the modif-off battle is on. I have a bit of a head start with this one, as i got the bike before Arran. Actually, he saw how cool it was and then decided to find one himself. 1979, pretty bad shape, but running and riding. Ill keep the updates coming. Archives
July 2012
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