[Rexus]

Hey fellow Fighter

I got the dinosaur a couple of years ago and bought it for a song, with the sole purpose of building a fighter after my own heart. With there roller bearing motors (Bullet Proof) I must just do a propper job and I know I will have years of hassel free riding.

The first problem that I got was some hack before me climbed into the wiring and cut here and joined ther and in the end I was looking a a crows nest. Just fooking horid, that people think they are pros because they can bypass the problem.

So I ripped out the whole harness and started from scratch, everything was new. Every switch, regulator, rec, fuse and joiin. I took 10 different wiring diagrams and worked from the ground up on all the parts that must be connected and made my own diagram. Unfortunately the only images that I have of that job vanished with my last laptop.

So one day on my way to work I took a shortcut and did not pay too much attention the the leaves that were piled up and when I hit the brakes going into the corner, the front slid out and I put her down. The only damage was the picup cover and the points down there.

So I put her in the garage till I was going to do the rebuild.

So some time down the line I got married, start my own business and moved twice.
Tha last move I have my own garage, with the tools setup and started with the strip.

I got onto Photoshop and knocked up the bike/look that I want to achieve. Will post that pic first.

Since I am new here and new at this sort of thing I will definately be asking for help and assistance. I have read many threads, got inspiration from CF that I just want to say that The guys who started and maitain this site, awesome guys. To the rest of us, noobs and pro alike, thanks for making this the goto place for any enthusiast.

Now... onto the build.

 

[Rexus]

So the first part was the STRIP.

I started with the frame, took off the rear suspension, forks, tank and ripped out the wiring.
Pulled the motor out and set up two piles.



The one pile was all the parts that I was going to keep and use on the build, the other pile was all the parts that I needed to throw away.

In doing so I was commited to the hilt. If I did not go ahead I would then effectively be throwing the whole thing away.

So I kept the frame, carbs, wiring, motor and a few sundries to help along the way.

 

[Rexus]

The next step was to strip the motor.

I went about it the normal way, turn everything that can be turned to the left. I hit one snag when trying to pull the head. As it turned out the problem needed a bigger hammer.

That was when i posted it here on this forum as a problem that needed to be solved.
I got some very quick replies and after the advise ran back down to the mancave wielding a mallet and a grin of determination. Wollop-wollop ... wallah! It was off.



Deeper still.



Now when I got to the top of the block I could see the burn marks where the gas was escaping between the block and the head on cylinders 2 & 3. So all the more reason to pull it apart, escaped gass = escaped ponies, can't have that.

 

[Rexus]

After the head was removed I had a hard time trying to split the bottom half of the motor.

I learnt from frustration that the clutch and all its pieces had to come out first.



So I foto'd every piece on my way out so as to not get lost going back in.











Discovered two plates behind the clutch with screws that head the the base part of the motor together. After I undid those screws she just slipped apart. Now everything was open.

 

[Rexus]

Along the way I had an afternoon alone in the mancave while the misses was out to build up the pick-up cover that was busted in the fall.

Used Steel putty to put it all back together.

Onces the putty was hard I jumped in with a file and sand paper to smooth it all out.







I figured that once I spray it it will be fine. Just need to be sure that it seats on the gasket. But nothing a bit of sanding cannot cure.

 

[Rexus]

Now that I was done stripping it was time to sort the lot out.

I put everything into boxes with compartments in the sequence that I stripped the bike in.









I also as a precaution wrapped the cams very safely so as to prevent any harm coming to them.

 

[Rexus]

Now that that has all been done the next point was to lay it all out and admire my progress.

I love doing this...:Evil_smile:

So on the floor of the mancave is everything.













Now I will work out what is to be done next.
Having the motor sent away this week, but this is where i am going to need some advise.

 

[Sheas Rebellion]

Just a heads up im sure a lot of ppl are gonna tell you about how yor headlight is junk.

 

[Rexus]

I like the two side-by-side lamps. I got it cheap, and will cut and reshape it to suit my needs.
The other more modern one cost a sweet penny this side of the pond.
Since Im cutting and then spraying it I guess it will do.

 

[Azharok]

You sir are CRAZY, I don't think I'd have the guts to gut a bike EVEN with a manual !!

REP and DW !!!

 

[Rexus]

You sir are CRAZY, I don't think I'd have the guts to gut a bike EVEN with a manual !!

REP and DW !!!

Thx mate. I figured go in for it all, and start with the motor.
Since this is my first I can only learn, just hoping my mistakes don't cost me too much.


Good decisions come from experience, and experience comes from bad decisions!!!

 

[piester]

besides the headlight it looks like a nice project

 

[Rexus]

The next task was the carbs.
Found them full of old fuel, bugger they stank.

Set out boxes to keep the order, so nothing screwed me around later.


and now sorted.

 

[Rexus]

Shit stinks...

 

[Rexus]

Got the motor back from blasting.
The guy has been doing this for 25 years.
Did a good job.

 

[Rexus]

Next was seating the valves in the head.
Used a drill with a hose and grinding paste.