howdy all, advice gratefully accepted as I know NOWT!!

[cactusmelba]

hey.

Been off bikes for twenty years, got myself a little project bike, a P.O.R Apache 125 that's been sat in a field feeling sorry for itself for a couple of years.

I want to get it running and back on the road, but really want to DO something to it first, customise it, make it look a bit more unique. I've seen some ideas of what I'd like to accomplish, but knowing NOTHING about engineering (but being VERY willing to learn) I'm going to be asking for advice on here a fair bit I think!

here it is when I got it..

http://i1349.photobucket.com/albums/p748/eugenebreakwater/Mobile%20Uploads/20131101_122012_zpsnpa5nodp.jpg

And here's the kinda thing I'm taking inspiration from...

http://i1349.photobucket.com/albums/p748/eugenebreakwater/Mobile%20Uploads/Honda450_lg_zps5kvzn7es.jpg

Yes, I KNOW it's a totally different layout with the suspension and the water cooler and all that, but the GENERAL shape, the stripped back street scrambler look, THAT's what I'd like to aim for. I'm going to need to hide a lot of stuff, re-position a lot of stuff, fabricate a seat unit, get a new tank, and GRIND a lot of stuff off!! And learn quickly. Can't wait!

Anyway. Hi all. Looking forward to picking your brains!

[FastDoc]

Welcome to the forum.

I don't get the Chinese... Who NAMES these things? A POR (poor) bike??

Oh well, moving on...

That CRF250 flat tracker is the cat's azz. Very cool. Nice inspiration for your project.

Brother Weld will chime in shortly with custom cafe suggestions; it's his thing ;-)

Looks like you will want 18" wheels laced to your original hubs, clubman style bars, lower suspension, delete the airbox, relocate the battery out of sight (I'd recommend a tiny lithium style one), a custom seat, maybe a tank off a 70's honda CB, an Edge II type tail light with integral blinkers, and a million other things! LOL!

Does the UK require a license plate the size of a barn door? That suckers gonna slow the whole bike!

[edtardo]

Welcome to the forum.

I don't get the Chinese... Who NAMES these things? A POR (poor) bike??



at least it doesn't say P.O.S on the side lol

[cactusmelba]

Hey, replies! Woop!

Thanks folks, to show you the level of ignorance you're dealing with I'll tell you now that I'm gonna have to Google 'hubs' 'lacing' and 'rims' to start with!

Oh, I forgot to say, I want to do it on a very tight budget too, ! I know, I'm asking too much for my own level of tech savvy, but I'm not expecting to achieve THAT bike, just an approximation. And I want to learn from this project, lessons I can apply to my next.

All comments are appreciated, all suggestions will be looked into and pondered over, and all comments about the ridiculous size of our STUPID UK number plates will be vociferously agreed with!

[cactusmelba]

Having stripped all useless unnecessary detritus from the bike, I've found multiple nests of small creatures, a whole load of rusted on bolts, and a couple of spots on the frame that need welding, on the rear engine mount brackets..

Got a mate coming round next week with a couple of old small tanks we can try for size. That'll define the lines of the bike I reckon.

http://i1349.photobucket.com/albums/p748/eugenebreakwater/20131225_161848_zps9bbf6f55.jpg

Does anyone know if the airbox can be taken off without taking the carb off? I've undone everything I can see, (3x cover screws, 3x box mounting bolts, 1x clip round the carb intake) but it ain't shifting yet..... There's not a lot of wiggle room in there.

[SpudRider]

Welcome; we are glad you joined us. :hi:

Do yourself a favor, and remove the carburetor before you remove the air box. The carb is neither difficult to remove, nor difficult to install once the air box is removed. You might also need to remove the shock absorber to remove the air box. ;)

[cactusmelba]

Thanks spud, I'll do just that. Nice zong btw!

[FastDoc]

A Brit that says 'Howdy' and has 'Cactus' in his screen name??

[cactusmelba]

A Brit that says 'Howdy' and has 'Cactus' in his screen name??

What can I say, I've watched too many movies and I feel an affinity with y'all!

[cactusmelba]

Looks like you will want 18" wheels laced to your original hubs

the rear is 18" now, front 21"..

Forgive my ignorance, but do wheels from cg's/xt's fit on these bikes? Or does it have to be from a P.O.S? I mean R.

[SpudRider]

What can I say, I've watched too many movies and I feel an affinity with y'all!

Hollywood strikes again! :lol: We have cactus plants in Idaho, but only the small, Prickly Pear Cactus. Nevertheless, these cactus plants are pretty when they flower in the spring. :tup:

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/Crenshaw4-16-11041.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/Crenshaw4-16-11045.jpg

[SpudRider]

the rear is 18" now, front 21"..

Forgive my ignorance, but do wheels from cg's/xt's fit on these bikes? Or does it have to be from a P.O.S? I mean R.

If you want to copy this Honda motorcycle, you probably want both wheels the same size.

http://i1349.photobucket.com/albums/p748/eugenebreakwater/Mobile%20Uploads/Honda450_lg_zps5kvzn7es.jpg

In this instance, it's easiest to make the front wheel an 18-inch wheel. If someone knows of a Chinese motorcycle with an appropriate, 18-inch front wheel, you can get one of them. Otherwise, you can buy 18-inch Zongshen spokes from Taobao, in China. If you buy spokes you will need to disassemble the current front wheel, and have someone rebuild the wheel with the shorter spokes.

[cactusmelba]

In this instance, it's easiest to make the front wheel an 18-inch wheel. If someone knows of a Chinese motorcycle with an appropriate, 18-inch front wheel, you can get one of them. Otherwise, you can buy 18-inch Zongshen spokes from Taobao, in China. If you buy spokes you will need to disassemble the current front wheel, and have someone rebuild the wheel with the shorter spokes.

Thanks mister spud, you're starting to appreciate what sort of level of incompetence you're dealing with here, I need it ALL spelling out!!

Thanks for your help dudes, it's much appreciated....

:tup:

[culcune]

Having stripped all useless unnecessary detritus from the bike, I've found multiple nests of small creatures, a whole load of rusted on bolts, and a couple of spots on the frame that need welding, on the rear engine mount brackets..

If there was any doubt before...you have a Chinese bike!!

I know that member 'Oengus' likes dirt tracker style bikes, but he hangs out on mychinamoto.com under the name 'MJH' far more than here for some reason.

BTW, welcome! And some of my best friends that live near me are cactus...

[Weldangrind]

Welcome!

I happen to be building a similar machine right now. If you examine the rear triangle (or subframe), you'll see a stud on either side that doesn't seem to have a purpose. On the left side, it is located just above and to the left of the battery, and there is another on the right in a coresponding spot. The frame is almost identical to the early 80's Honda XR185 / XR200, and those studs would be used for twin shocks. If you want to get the bike a little lower (and more street tracker-like), twin XR200 shocks on the back and XR200 forks on the front is one way to go.

As well, the early XR200 gas tank is almost a drop-on fit, since the frames are so similar. I haven't sorted the front wheel out yet, other than lacing an 18" rim to the XR200 front hub and using the drum brake.

You and I can compare notes as we go along.

[cactusmelba]

OOh interesting, all the bikes that caught my eye when I was looking for inspiration were twin shockers.....

I'll check that out tomorrow. The thing is , I REALLY don't want to spend a lot on the build, as it's probably not going to be a bike that I'll keep, I just want to learn something about motorcycle engineering, how everything works, the pitfalls to customising, all that guff!

Of course all that could change if I fall in love with it !

[Weldangrind]

I forgot to mention that if you deleted the monoshock and installed twin shocks, the twin shock XR200 swingarm is a bolt-on deal.

[Weldangrind]

Here's what I mean: http://www.chinariders.net/showthread.php?t=12613

[cactusmelba]

Here's what I mean: http://www.chinariders.net/showthread.php?t=12613

That's a VERY handy thread, good work sir. Any updates?

I'm not confident enough to go that far yet, and I can't weld, but I'd really like to see if you've gotten any further on those bikes yet?

[Weldangrind]

Not yet. Bro-in-law and I were hoping to work on the bike over Christmas, but there was no time. He's gonna try and get back to my place in January, and we'll hopefully get back on the project.

[cactusmelba]

http://i1349.photobucket.com/albums/p748/eugenebreakwater/Mobile%20Uploads/2014-01/IMG_20140118_170851_zps2pzgxfnb.jpg (http://s1349.photobucket.com/user/eugenebreakwater/media/Mobile%20Uploads/2014-01/IMG_20140118_170851_zps2pzgxfnb.jpg.html)

Just an update, for anyone who's following this thread, I've decided on the tank and bars, but I can't get her started... (see other thread!) I still need to source an 18" front wheel, but with the tank decided upon, I can plan out the fabrication of the seat and try to hide as much gubbins underneath it as possible...

I really want to make sure it's running right at every stage of the build though, so I know that if suddenly it's NOT running, the cause is whatever I've JUST been messing with!

[cactusmelba]

Ok - more "progress"!

Started to strip all the electrical gubbins from their lazy assed untidy frame mountings and grind off all unnecessary bracketry to clear up the magic triangle..

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/20140317_235753_zpsyuyn25ef.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/20140317_235753_zpsyuyn25ef.jpg.html)

And started to fabricate a template for an under-seat tray to house aforementioned electrics, including the battery.

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/20140317_235731_zpsqyuuaevj.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/20140317_235731_zpsqyuuaevj.jpg.html)

Here's the tray bent into shape.. (from a piece of rusted steel I found in a skip)

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/20140323_111254_zps1axceglp.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/20140323_111254_zps1axceglp.jpg.html)

And in situ...

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/20140323_111356_zpsezkbtgue.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/20140323_111356_zpsezkbtgue.jpg.html)

Decided on the tank to use, but it had a massive dent in it, and an opening at the back end that needed filling..

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/20140405_175654_zpsnh1ftp8w.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/20140405_175654_zpsnh1ftp8w.jpg.html)

So cut a metal plate to fill the back opening of the tank and cracked open the stinky filler..

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/20140424_224259_zpsyk8jqagw.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/20140424_224259_zpsyk8jqagw.jpg.html)

Started fabricating a wooden ply base for the seat, and ground off a good 8 inches of frame from the back of the bike.

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/20140602_105508_zpsignzyfw8.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/20140602_105508_zpsignzyfw8.jpg.html)

And messing around with foam (cut out of the original seat foam of course)

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140713_235804451_HDR_zpsq7ywq7op.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140713_235804451_HDR_zpsq7ywq7op.jpg.html)

Cut a recess for the cheap chinese ebay light and number plate bracket to fit into.

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140701_194851446_HDR_zpsrygffv21.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140701_194851446_HDR_zpsrygffv21.jpg.html)

And where I'm up to right now, started stitching my own seat cover out of an old tan leather (real leather) sofa cushion cover I found rotting in a customer's garden.

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140724_195944865_HDR_zpsqgwbiuf3.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140724_195944865_HDR_zpsqgwbiuf3.jpg.html)

I know it still looks rough as hell, but I've never done anything like this before and I'm pretty chuffed with the way it's going so far. It's really taking shape, and what's more is that I've spent under £50 so far, with the only expenditure being a new gel battery and the back light... Anyone wanna sell me a front light dirt cheap?

I realise a 'street tracker' look might not appeal to most, but I like the way it's going!

[SpudRider]

Thanks for posting the update. You are making good progress. :)

[Weldangrind]

Love it! I agree with you on cleaning up the triangle. The welds are just awful on these frames, aren't they? I have tons of grinding to do on my project.

[bogieboy]

absolutely love your ideas bro!!!! looking forward to seeing more progress!!!

[Weldangrind]

What is the tank from?

[cactusmelba]

What is the tank from?

good question!

it was kickin around in a car importers place along with a couple of other m/cycle bits and bobs, origin unknown I'm afraid!

Our local bikemonger reckons it might've been an old quad bike tank or something similar... Cute though innit!

[zingshoen]

street tracker sounds good to me. do you have a picture of the whole bike as it looks now? are u going to keep the handlebars?

[Weldangrind]

good question!

it was kickin around in a car importers place along with a couple of other m/cycle bits and bobs, origin unknown I'm afraid!

Our local bikemonger reckons it might've been an old quad bike tank or something similar... Cute though innit!

It really has a nice shape for the look you're after. :tup:

[cactusmelba]

Oh, I forgot... A couple of other things altered so far... I've relocated the ignition to just underneath the tank, with a custom bracket made from another scrap bit of metal..

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140731_152506461_HDR_zpsj6qg4epv.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140731_152506461_HDR_zpsj6qg4epv.jpg.html)

Here's how it looks with the tank on...

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140731_152442869_HDR_zpsgpta2koq.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140731_152442869_HDR_zpsgpta2koq.jpg.html)

And I made a new bracket for some tiny clicks a mate gave me... (not entirely sure they work yet, that could've been a waste of time!)

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140731_152431183_HDR_zpsbuhzpura.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140731_152431183_HDR_zpsbuhzpura.jpg.html)

I'll take a picture of the whole thing soon, just glueing some leather right now!

[Weldangrind]

I like the ignition location and the tiny speedometer. Looking forward to more...

[cactusmelba]

Finally finished stitching and gluing the seat base leather today, the seat BASE is finished now, just got to cut and sew a pad to sit on..

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140802_163556289_HDR_zpsjoihtl10.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140802_163556289_HDR_zpsjoihtl10.jpg.html)

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140802_163538029_HDR_zpsq9a3yqzy.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140802_163538029_HDR_zpsq9a3yqzy.jpg.html)

And here's a pic of the overall stance so far...

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140802_171228_zpsqa8tp3wm.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140802_171228_zpsqa8tp3wm.jpg.html)

Quick question though, the tank has no tap, and it has two tubes coming out of it. I'm presuming one will be a breather pipe to the inside of the tank and the other will be fuel?
I'm prolly gonna swill it round with some fuel to clean it out a little, and I'll take note of which tube the fuel comes out of.. Have you guys seen this type of fuel outlet before? I presume (once again) that I'll just need a simple in line fuel tap with a filter before it?

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140802_170925_zpsywkx2qp1.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140802_170925_zpsywkx2qp1.jpg.html)

[Weldangrind]

Remarkable! Did you stitch the leather on a machine? I want to learn that skill. Please show us a pic from the side with the seat installed.

I would remove the gas cap and fish a piece of wire up through each tube and see where it comes out. That should tell you if one is a breather, or if one is reserve.

Dave just cleaned his tank by soaking it in vinegar, and I've heard that apple cider vinegar is the most effective. After you rinse it out, be sure to blow out as much air as possible, and then slosh some sort of lubricant around inside the tank to prevent flash rusting.

If both tubes are meant to be fuel lines, the shorter one is reserve. You'd either need two taps and filters, or one switchable inline tap and one filter.

[cactusmelba]

Well.

I never in my wildest dreams have expected a "remarkable" from ANY experienced bike modder! Thanks man!

The stitching was done by hand, but I only had to switch one seam, the one that goes up and over the hump on the front edge. I've never sewn a thing before, and I knew it wasn't going to be neat so I made it a hidden seam, tucked away inside out. Then I glued the whole thing down so there wasn't any stress on my stitching!

The other seams were already there on the cushion in the original design.

I pushed some wire through the tank outlets, but it's such a tiny filler hole, you can't see where they come out, and I couldn't tell what was going on by touch. I'll stick a bit of fuel in and see if it comes out of just one outlet, that should tell me something, (although I'm not entirely sure what!

Here's a pic of the seat unit mounted...

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140803_150624569_zpsnofacl4b.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140803_150624569_zpsnofacl4b.jpg.html)

[Weldangrind]

The other seams were already there on the cushion in the original design.

That's genius. You made the original seams work with your design. That must have taken some careful planning.

Rather than fuel, you may wish to try water. I'd slowly fill the tank until water comes out of one of the tubes, and then plug it. Continue filling until it comes out of the second tube. The water that the first tube flowed out of is reserve. As mentioned before, get the tank as dry as possible after and then slosh some lubricant in it.

Thanks for the profile pic; I really like the shape. I especially like how you relieved the bum stop to accomodate the tail light.

[cactusmelba]

Thanks brother weld,

I can't count the number of hours I've spent just stood in the garage LOOKING at the bike and working stuff out.. It's been quite an exercise!

And thank you for the tip about filling it slowly, that makes perfect sense to me. I'll be doing that next as I want to get her fired up again to make sure all is working as it should be.

What sort of lubricant should I use after swilling the tank out?

[Weldangrind]

Not sure what you have available to you in the UK. I would use liquid WD-40, except that it's rather costly. I think that Varsol is another good option. You might also be able to use acetone, because it will evaporate in seconds in the hot sun. The point is to find something that will displace any remaining water and then be compatible with petrol; Varsol is petroleum-based, so I think it's suitable.

I get the process, and how you have to stare at it, visualize the negative space and imagine how you'd like it to look. You're doing a great job. May we see a profile pic of the tank?

[cactusmelba]

You may indeed!

It's still a bit scraggy, I've a lot of filling and sanding to do yet... Open to suggestions on colour though!

http://i488.photobucket.com/albums/rr242/cactusmelba/Mobile%20Uploads/IMG_20140804_200233168_zpssd79aq5p.jpg (http://s488.photobucket.com/user/cactusmelba/media/Mobile%20Uploads/IMG_20140804_200233168_zpssd79aq5p.jpg.html)

[Weldangrind]

I thought I saw knee indents in the tank before. Did you fill them?

BTW, love your Monty Python avatar!

[cactusmelba]

There was ONE indent on the side you can see, the previous owner had tried making his own indent but not bothered to do the other side... I decided I wanted it non-indented so had to fill the thing level!

(btw it's not monty python, it's noel fielding, he's about three levels more insane than python!

[Weldangrind]

I had to look up Noel Fielding. He lists his primary influence as MP.

With that seat colour, I'd pick either a dark red or a dark blue.

[zingshoen]

orange is the new black! i d go orange, a hue that goes with the leather.

[cactusmelba]

Funny, the tank was originally orange, and I'd been toying with the idea of blue as well, as a contrast.... Plenty to do before that decision......!

[Weldangrind]

I like orange a lot, but to me, the seat would be lost with an orange background. With a dark blue, the seat would be the focal point.

[cactusmelba]

Micro update.

Finally got round to cleaning the tank out, I just swilled some fuel round with some rocks inside the tank to loosen any loose material. Seemed to work, a few flakes and dirty fuel to throw away, ready for the new tap to go on..

http://i488.photobucket.com/albums/rr242/cactusmelba/IMG_20140811_104823115_zpsq5dzxnti.jpg (http://s488.photobucket.com/user/cactusmelba/media/IMG_20140811_104823115_zpsq5dzxnti.jpg.html)

And had to bodge a small metal bracket to hang the fuel tap on. Found out which outlet was primary fuel and which one was reserve, then decided to just join the two with a 'y' splitter and use a simple tap instead. Reserve is for wimps!

http://i488.photobucket.com/albums/rr242/cactusmelba/IMG_20140811_164422_zpshrwm4ujt.jpg (http://s488.photobucket.com/user/cactusmelba/media/IMG_20140811_164422_zpshrwm4ujt.jpg.html)


Also, I gave up trying to hand stitch my own seat pad after two hours of futile seamstressing in the garage the other night. Found a little old lady upholsterer locally who said she'd do it cheap. And she did!

http://i488.photobucket.com/albums/rr242/cactusmelba/IMG_20140811_165000085_zpsrmnxyarw.jpg (http://s488.photobucket.com/user/cactusmelba/media/IMG_20140811_165000085_zpsrmnxyarw.jpg.html)

Could have done with a line of stitching around the edge of the whole pad really, not loving the zigzagging effect, I might ask her to do that sometime... Seat looks better with a pad on though...

http://i488.photobucket.com/albums/rr242/cactusmelba/IMG_20140811_165024845_zpssp2uzfxl.jpg (http://s488.photobucket.com/user/cactusmelba/media/IMG_20140811_165024845_zpssp2uzfxl.jpg.html)

So here's how she stands right now. Fuelled and a non starter again for some reason. Must've dislodged some electrics somewhere.. 😕

(what does it mean when fuel drips out of the overflow /breather that exits from the very bottom of the carb? It was dripping for a while when I first put fuel in and while the furl tap was turned on. It would stop dripping if I turned the fuel tap off, but if I turned it on again and tried starting it a few times it stopped. Now it's fine. No drips, but fuel tap left turned on. Odd.)

http://i488.photobucket.com/albums/rr242/cactusmelba/IMG_20140811_160920_zpsq0num7j7.jpg (http://s488.photobucket.com/user/cactusmelba/media/IMG_20140811_160920_zpsq0num7j7.jpg.html)

[Weldangrind]

Excellent progress. Good call on farming out the stitching.

Your needle and seat isn't seating. Perhaps something from the carb got caught in the seat, and that could help explain the no-start condition. Perhaps the slow and main jets are also clogged. After you clean them, I recommend that you install an inline filter. Whatever debris is left in the tank will head straight for the carb.

[cactusmelba]

Thanks Weldmeister, I'll whip the carb off, clean it out, and get a fuel filter too..

Another issue is that I was trying to re-fit the front calliper onto the forks but I can't prise apart the pads.. I tried to unscrew the lid on the hydraulic fluid chamber box mounted on the handlebars (I'm sure there's a more technical name for it than that but I personally don't know what it is!) to see if that would relieve a little pressure but the screws are SOLID. Instead I undid a little bleed nipple on the calliper itself until a little fluid came out then held it higher that the handlebars while I tried to prise the pads apart but no luck.

What am I doing wrong? (and don't say "playing at being a bike mechanic!")

[bogieboy]

sounds like a stuck caliper to me... mine were quite easy to pry apart when i dd my supermoto conversion... i actually just wiggled the caliper on the disk by hand to loosen the pads for the wider rotors of the ninja rims... you may need a new caliper or a rebuild, especially if they wont budge with the bleeder open... what are you using to try and move the pads? i usually use a large (1/4" or 6-8mm wide) flat blade screw driver...

[cactusmelba]

Yep, just a large screwdriver. The housing moves but the pads barely move at all... Weird as they've only been off for a few weeks and were fine up to then... I'll try to adjust it's attitude with my hammer and see if anything alters ..

[bogieboy]

silly question but can the pads go in if you squeze the lever? dont go a lot, but maybe see if the piston just got a bit stuck?

[cactusmelba]

silly question but can the pads go in if you squeze the lever? dont go a lot, but maybe see if the piston just got a bit stuck?

No. nothing's moving at all....

[bogieboy]

hmm... that seems to be an issue then... i assume the lever gets hard, like its building pressure? otherwise you might have a bad master cylinder... the piston on the caliper should be fairly easy to move...

[cactusmelba]

Hi all,

no real progress to report, but I think I might have found out why it's not starting.. I've mounted all the electrics under the seat on a tray, and I've just been reading that some ignition coils need to be mounted on the frame to complete the loop or something, whereas mine's just sat on the tray!
I'll get it mounted onto a bracket and see if that works!


And where did I read this nugget of information that's probably basic common sense to you guys?

For my anniversary my mate bought me a "chinese 125's Haynes manual" that includes the POR Apache 125!

Best . Present . Ever!




Not tried to do anything with the brakes yet. I'll consult my manual!!

[Weldangrind]

Hilarious! I never knew that manual existed. Please feel free to share bits of wisdom from that manual as you find stuff.

[SpudRider]

Thanks for posting the good tip on the Haynes Service Manual. :tup:

http://i.ebayimg.com/00/s/NTk5WDQ1MA==/z/75YAAOSwVFlT1TKd/$_1.JPG

http://www.amazon.com/Chinese-Motorcycles-Service-Motorcycle-Manuals/dp/1844258718

[cactusmelba]

That's the one!

Got a spark now, mounting the coil on the frame clearly helped!

[Weldangrind]

I guess your coil achieved ground by attaching to the frame. Some do, while others have a dedicated ground wire.

[cactusmelba]

Hi All,

After a long cold winter when the only time I ventured into the garage was to get firewood, I've finally started tinkering on the bike again, and I'd like some advice on jets/mixture please.

I've got the bike running, ticking over lumpily, and starting first kick. The problem is that it doesn't seem to be revving more than about 2k revs while riding. (I'm guessing as I haven't got a rev counter any more). It'll rev, and accelerate , then at about 2k revs it'll bog down and hit a total flat spot. At that point if I reach under and tickle the choke it'll rev higher and accelerate more.

Does that mean it's running too lean?

And will that be because I've taken the air box off and put an air filter on instead?

http://i1349.photobucket.com/albums/p748/eugenebreakwater/IMG_20150321_152056735_HDR_zpsetmihig8.jpg (http://s1349.photobucket.com/user/eugenebreakwater/media/IMG_20150321_152056735_HDR_zpsetmihig8.jpg.html)

[Weldangrind]

Please save me from reading the thread again. What size engine do you have, and which carb are you using?

[cactusmelba]

Hi Weld,

It's a POR Apache, (GY125) running the stock carb , whatever that is. I've not re-jetted or anything yet, but I HAVE removed the airbox and installed a wire mesh filter that I found. Original exhaust is still on for the moment but I'm taking it in to get a new one made up so I can re-route it and make it shorter.

It starts nicely, first kick (with a little choke) but the problem is that when it's warm, it'll only rev to about 2k then hit a flat spot. If I reach down and tickle the choke while I'm riding then it'll rev much higher and pull off better. (I haven't actually got a choke cable on it at the moment otherwise I'd leave it open a little!)

Thanks for reading mate!

[Weldangrind]

When you say you'd leave it open a bit, does that mean you're trying to ride with the choke closed?

[cactusmelba]

Correct.

I've waited till it's warm and ticking over without any choke before riding it. So when I'm riding, there's no choke on at all. But if I open it a little, it immediately pulls better and is allowed to rev higher.

[Weldangrind]

Perhaps we're using dissimilar terminologies. You said "So when I'm riding, there's no choke on at all. But if I open it a little, it immediately pulls better and is allowed to rev higher." That appears to be a contradiction to me, since you can't open a choke that's already open.

Perhaps you are riding with the choke at least partly closed, and you're finding that it runs better with the choke fully opened. Does that sound correct?

[cactusmelba]

oh oh, I must be wording it wrongly!

let's clarify, in the default position, I consider the choke 'closed'.
If the engine is cold, I move the lever from the default 'closed' position, to allow more (air? fuel? one of the two!) through.

This is exactly what I have to do while riding to get the bike to rev further through the rev range.

There's no actual choke cable on the bike, just the little lever on the side of the carb, so I can't operate the choke as well as I should be able to.

As soon as the bike is warm, it ticks over ok without any help from the choke. but it won't rev through the whole range WITHOUT me operating the choke.

Clear as mud eh?

[Adjuster]

Default position is choke fully open.

Your choke should always be fully open.

Remove your air cleaner and examine the choke plate if there is any confusion.

If starting cold say 40 degrees or colder you may need to apply some choke.(I live in Florida and have never had to apply choke for cold start)

You should always attempt to start the engine with no choke and only apply/close the choke if needed.

If you do need to apply choke to start the bike after approximately 2 minutes the bike should be sufficiently warmed up for no choke(completely open).

You should in almost all circumstances only be riding the bike with no choke(completely open).

What is the temperature where you live and currently starting and riding the bike? 50 degrees or more and you should not need any choke(full open).

If you are needing to close the choke even the slightest amount to keep the bike running after it is fully warmed up then there is something else wrong and likely your carburetor needs some attention/cleaning/adjusting.

What octane gas are you running?



/

[cactusmelba]

Ahhh, now I see where I'm going wrong! I'm causing confusion, I'm sorry!!

I'll describe it again using the correct terminology....

From cold, (and it IS cold, frosty) I have to start the bike with choke closed. After a couple of minutes the bike warms enough to idle with out choke (open). When riding, revs are limited to a couple of thousand revs, but if I reach down and close the choke a little, then the full rev range is restored.

So I'm aware that the carb needs attention, and I'm presuming that it needs re-jetting as the mix appears to be wrong. From that description, would you guys agree?

(sorry for the confusion, I had totally the wrong idea about describing the choke action!!)

[Mudflap]

It's running lean. Before replacing jets I would move the jet needle clip one notch richer.

Edit: I see it has a pod filter so in addition to moving the clip you will probably have to get a larger main jet.

[cactusmelba]

Thanks mudflap, I'll do just that.. I've seen cheap jet kits on eBay from China for about ten quid that contain 5 different size jets, or there's a UK seller that does individual jets for a fiver. I've no idea what size I've got or need, but I'll do some research. And I'll Google 'jet needle clip' too!

Don't despair, we've all gotta start somewhere!

[Mudflap]

The setup on my Lifan is similar. OHV 200 with exhaust opened up a bit and a pod filter on a Keihin type 30mm carb. Seems like I ended up with a 108 main jet.

[Weldangrind]

If you remove the existing main jet, you might find the size stamped on it. Moving the clip might help, but the clip only affects the mid-range.

[cactusmelba]

Great, thanks for the help!

I've ordered myself a set of 5 jets.

If the current jet is, say, a 95, I wanna go UP to a higher number right?

[Weldangrind]

Correct. For the most part, the jet sizes correspond to millimetres. A 95 main jet = 0.95mm.