Dutchie is Running

brownb0x — Thu, 21 May 2009 00:46:31 +0000

Sweet, got the first of 3 running today. It is great on the flats, but uphill is a whole different ballgame. It is like accelerating up a cliff when I ride up a slight grade.

I’ll take the exhaust off and clean it, as I’m pretty sure it hasn’t been done in a while, if ever.

As a side note, the petcock I used was an OMG from a Magnum, which is also 15.5mm.

Project Bikes Update

brownb0x — Sat, 16 May 2009 23:22:41 +0000

So, after cleaning and soaking all three carbs, each of which is quite different than the Puch Bing, although the Flying Dutchman has a square bing, which is similar…I have determined that I need the following to start getting these guys running:

Flying Dutchman Petcock…bigger than Pug, Gar or Puch’s. (I may just end up making an adapter for the fuel tank petcock connection so I can use a standardized nut size, but we’ll see…)
Garelli Starter Assembly (prolly just do a complete regrip w/ decomp)
Regrip Pug as well w/ decomp
Regrip Dutchie w/ decomp
Pug belt
Clear Fuel Line tubing (I do hate the opaque tubing where you can’t see fuel flow…)
New spark plugs for all 3
3 sets 16″x2.25″ tires
Bronze Brillo Pad and Chrome Polish

I’m going to start on the petcock issue on the Dutchie, because I am of the opinion that it’s most likely the only thing keeping it from starting. Then we’ll go from there.

If anyone knows of a place to find larger intake ported petcocks, I’d love to know where you can find them. Hit me up.

Peace duders.

3 New Project Bikes

brownb0x — Thu, 14 May 2009 14:21:03 +0000

Here are some pics of the 3 project bikes I just got today…

I’m so excited. I’m soaking carbs now.

1980 Peugot 102SP

1978 Garelli

1977 Flying Dutchman

I’ve got my work cut out for me and I can’t wait to get started.

Click through to the Halfwits Sorcery Flickr Pool on the right to see more pics.

Got the Puch Running Again!

brownb0x — Sat, 09 May 2009 16:31:31 +0000

So, after the ZA50 work and replacing the case bearings for the new case cover my Sport MKII is running like a champ again. I can’t wait to get it back on some proper rides.

Jed has offered tolet me borrow his 50cc hi-comp head, so we’ll see what that does for performance, but I ended up taking the hi-flow air filter off and replacing it with the stock airbox because I was just running way too lean. It immediately shot back up from 25 on flats to 30+ again, so things seem to be right in the universe again. Next purchase will be a performance exhaust, but for now the derestricted stock pipe shall have to do.

I’ve added the bearing removal and installation videos to the ZA50 breakdown post, but there’s really not much to it unless you just wanna see how I did it. Otherwise, here are the basic instructions from what I did:

Heat gun set at 1100°F, heat up the inside of the case around each bearing for a few minutes and turn it over and slam it against a smooth hard surface a couple times. Bearings just fall right out with a little cajoling. Then after having your new bearings in the fridge for a half an hour or so (I hear you can blast them with an upside down compressed air can to cool them sufficiently as well), heat up the case around one bearing inset at a time and drop them in. I used a rubber mallet and the handle of my 1/2″ ratchet, which fit perfectly onto the inner race of each bearing ring, to tap into place. You shouldn’t have to tap very hard if the case is heated enough and the bearings are cool enough. Mine went right in.

ZA50 Breakdown Videos

brownb0x — Mon, 20 Apr 2009 19:15:38 +0000

My Puch Sport MKII’s ZA50 had a loose 1st gear nut and after pulling away from a stoplight, it blew the bearing ring out through the clutch case cover. Here is the breakdown and reassembly I had to do to get it running again.

This was the first time I ever took apart my motor, so please excuse the fact that I may have used the wrong terminologies at times…however, I feel SO much closer and more in tune with my bike now that it’s running again. Hopefully these videos will help some people know what to expect when they open up their case and not have to experience some of the trials and tribulations that I faced going in.

VIDEOS AFTER THE JUMP.

ZA50 First Opening

Looking at the 1st Gear and Clutch Bell

** I forgot to turn the video camera on when I took off the 1st and 2nd gear clutches, but the only thing to note is the lock washer, which I explain later in retrospect while reassembling the clutches.

The 2nd Gear

Removing 2nd Gear Loctite Threadlocked Screws

Melted Puck Showcase…this was to be expected

Cleaning 2nd Gear After Torching the Screws is Easy

Breakdown of the Disassembled 2nd Gear

Scraping Melted Shift Dampeners; or Puck You, Melted Plastic

Assembling 2nd Gear and Installing New Pucks

Threadlocking 101 – Loctite Blue

Installing 2nd Gear

2nd Gear Clutch Install

1st Gear Clutch Install

Clutch Lock Washer and Nut – As far as I can tell, this is the only video on the net that actually shows what’s up with this thing…

1st Gear Install

1st Gear Bearings

WEWT. All done. My bike is running, and I think I’ll go for a ride now.

1/2W for life.

UPDATE:

Case Cover Bearings Removal – Disregard the part where I mention knocking the post all the way into the case, it was early in the morning and there is no way to do that since they are set into a stop to keep them from going too far in…that said, still make sure they’ve been removed because it won’t work if they’re in the case cover.

Case Cover Bearings Installation

Rat Pug Build up part 3

bemor187 — Mon, 20 Apr 2009 17:56:21 +0000

Well the bike is 99% together. I got everything together except i am missing the parmakit o ring for the water seal on the cylinder kit. Burn.. I checked the interenets but to no alas. I emailed treats, so we shall see soon…..

camera broke so no pictures…..

Rat Pug Build Up part 2

bemor187 — Wed, 15 Apr 2009 18:22:07 +0000

Back to the shop for more fixings and pleasantries. I am building a monster.

Polini 4 petal reed case
ParmaKit Crank
ParmaKit 70cc 46mm water cooled cylinder kit
19 mm dellorto sha
Polini Radiator
Bosch auxilary water pump from a MB slk230
BikePuter (for accurate Mph)

All parts except the radiator arrived by yesterday. I got the motor together tonight, It well oiled and sealed up. The stator and the clutch have been installed. Tomorrow I will put it back on the bike, hook up the carb and attempt to crank and tune it.

PHOTO JAM PART 2

monglo — Sat, 11 Apr 2009 04:50:32 +0000

thems some bikes right there

gotta catch em alllll

bikezzzz

more bikes!

PHOTO JAM

monglo — Sat, 11 Apr 2009 04:44:01 +0000

we need a table!

FREEEEEEEEE FALLLIINNNNNN

goes in the mouth

messy

Korado!

dude we hard. watchout.

RatPug 103 Build up

bemor187 — Fri, 03 Apr 2009 18:07:51 +0000

For those of you who dont know. I recently came across a peugeot 103. I started with some easy stuff.
dellorto 15.15, polini 4 petal reed block, split twin exhaust, cafe bars, and removed all of the fenders and seat mount and mounting a long seat on the rack, and a puch ignition, I removed 3 balls from the clutch for a little better pick up off the line. It is alright but not nearly fast enough.

Bemor <3 RatPug

a few mods

fishnets, new shoes for my girlfriend

So The Saga Continues.