Posts Tagged 'puch'

Tomahawk Cup race bike

Don’t know what the Tomahawk Cup is? read this! – http://www.mopedarmy.com/forums/read.php?1,3527560,page=1

These are the classes as they were hashed out and as they currently stand –

Stockish Class
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– No custom frames
– Pedals or Kickstart
– Stock Cylinder ONLY
– 15 mm carb limit
– Aftermarket pipe allowed
– Variated bikes allowed with no launch lever
– Any factory chassis or engine parts can be swapped to build a stock frankenbike.

Non-Variated Class
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– < 75cc Kits air cooled
– No carb limit
– 1 and 2 speeds
– Moped H20 < 50cc kits

Variated Class
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– < 75cc kits air cooled
– Bo carb limit
– Moped H20 < 50cc kits

Unlimited Class
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– < 99cc kits

While I have a billion projects, a few of which might be fun in some of those classes, I decided to do a Puch E50 build for the non-variated class. I have already done the crazy, complicated, weirdo concept super race bike thing for the Polini Cup all those years ago and was totally burned when no one showed up to race and the series got canceled, so I decided I would build something simple, easy and, most importantly, CHEAP to go racing with. Worst case scenario – this race circuit bombs like the Polini Cup and I have a super rad Maxi to rip around on that didn’t cost a bunch of money and end up too much a headache to put on the street (ala VX4).

Chris Paz hooked me up with a frame. Well, most of a frame. It’s going to need some stuff welded back on, namely some shock mounts, but it’s free and a rad platform to build on!
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I may take his work further and cut the seatpost part of the frame off and just build something out of tube steel to sit on, I’m not sure yet.

Other parts I already have laying around are a set of E50 cases, a 17″ disk brake front wheel, a couple different french bike pipes to choose from (Doppler and Doppler clones, I think? Not much of a choice really.), and this thingy-
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KTM 50 CDI, same setup I’ve been running on ciaociao for yeeeears. Mr. Naz up in Seattle built this for someone forever ago and I ended up with it.
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It’ll be perfect!

My plan for the engine build is going to be a heavily ported Gila on that 77 stuffy crank with the 77 Super Clutch. I’m going to use a pull start, so I’ll ditch the stock starting bits and cut the starting plate off the clutch to lighten it up some. I’ve also got some clutch bell mods in store, as well as lightening the main gear. I’m going to balance all those bits too while I’m at it.
I’ll probably run one of the 24mm carbs I have laying around.

The new Garage will be out soon and I’ll be documenting the build over there, but I’ll link it up over here too when ever I have updates.

This should be a fun build! I can’t wait to get back on the track!

Projects

Finally got everything from SF. Now to get organized and get busy!
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This isn’t all of them, there’s still the Motobecane VLX, Critical Miss, HobBAD Sparkle Butt, Ciao Ciao and the other DR350. But now everything’s more or less in one place and I’ve got my tools. I’m stoked!

dirtbag challenge 2013 bike – critical miss v1

ryan and i dragged out the kawasaki roadrunner we tried to build a few years ago and made it our 2013 dirtbag build. everything we did all those years ago had to be done over, but in the end it turned out to be a fun little ripper.
well, until the piston melted down on the dirtbag ride. as it turns out, taking a 46 year old 120cc two stroke trail bike with stock gearing out on the freeway for miles isn’t a great idea. who would have thought?
obviously we didn’t “finish” it, but with ~$300 and probably ~15-20 hours invested, we didn’t do that bad. the bike had been sitting in a guy’s back yard for 20 years or more when we got it and i had to break up the stock piston with a hammer to get it out of the cylinder. we are pretty stoked we even got it running in time for the dbc.
we have a new piston and ryan will be rehashing it next year for his dirtbag 2014 bike and i’ll be building something new, so i figured i’d get some shitty pictures of version one before that happens.

video of the first start at the bottom!

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hobbAD – Wooly Bullies 2013 raffle bike

thanks bully buddies, i’ll get around to it sooner or later!

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L’s magnum and some laguna stuff!

a while ago i got L’s magnum up on my lift to pull apart the transmission and check out the shift pucks. the bike has 201 miles on it, but it has been sitting for many years and i didn’t want to just assume they were still in good shape.

well, they totally were.
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everything in there was in great shape. totally not suprised, the whole bike is clean and in good shape. it was just one of those better-safe-than-sorry things.
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besides, i still had the low mile PAZ pucks that were removed from sparkle butt when the prototype atomic pucks went in. since i had this thing opened up, i figured i’d throw them in.
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i threw on a new clutch cover gasket and sealed everything back up and topped it off with atf.
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since i’m putting this thing back on the road for L, and this is pretty much her first real 2 wheeled ride out side of bicycles and the hobbit she rode around for a bit, i am making it as little and compact as possible. i decided the rack had to go (though i’m keeping it so that it can be thrown back on for possible camping adventures or whatever) and the rear fended needed bobbed so that the tire was the thing that stuck out the furthest.
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first pulled the carb to run it through our ultrasonic cleaner. it’s always a good idea to get that going while you’re doing other stuff to minimize sitting around time. while the carb’s cooking, i can take care of little stuff.
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new fuel line, fuel filter. stuck a drill to the crank and turned it over enough to make sure the oil pump is pumping as it should. replaced the starting cable.
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pulled the rear fender off and removed the tail light, then kinda eyeballed where i wanted the fender to end, rolled the fender back and chopped off the front of it to retain the stock lip on the rear (and keep that sweet ‘the marvelous moped’ sticker intact).
the carb was done by this point, so i rebuilt and reinstalled it.
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i picked up a little led tail light for the rear. i think the stock lighting coil should run it ok? we’ll see. i haven’t mounted it up yet, because i’m still trying to decide if i want to drill holes in that perfect trunk or not. i did run the wires for it, though.
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with the carb reinstalled, pump working as it should and a new sparkplug thrown in, i hooked up a fuel iv and fired it up with my drill. the thing started right up and proceeded to smoke out the whole 2nd floor of our building. it was awesome.
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i’ve since installed a new petcock after unsuccessfully rebuilding the stock tap (i can’t find a proper rubber piece for it) and replaced the left hand grip. i also pulled the pipe apart and cleaned it out as best as i could, but it’s still pretty smokey.
i need to get some brake knarps, trim up the stock brake cables and then i can go ride the thing around and hopefully burn out the rest of the junk in the pipe.
then it’s a matter of wiring it up proper and getting the plate for it and L can finally start ripping it around sacramento!

in other news, the kickstart guts for the laguna’s gpr engine finally showed up from europe!
so i pulled the clutch cover on that engine and went to work installing the parts.
it required me to remove the clutch itself, which i wanted to do while i was in there anyway. the clutch pads look alright, maybe a tiny bit worn. i think they will be fine for now. also, it’s got yellow springs in the clutch, i have no idea if those are stock or not.
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everything where it goes.
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i don’t have a replacement clutch cover gasket just yet, so it’s not quite ready to go all back together, plus i need to fix some shady stuff the previous owner did to this engine. for example, see those marks on the clutch’s face plate? they are from the oil level bolt being replace with one that was too long, it was dragging on the clutch. how do you not notice that?

i also remembered that the previous owner had said the cylinder had some porting done to it. i figured now was as good a time as any to pop the top off and have a look. the porting is actually pretty ok. everything looks clean and nothing looks horrible. i’ll run it as is.
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i bolted the engine back together loosely until i get new gaskets for everything, and put it aside. i hope to be able to afford to get the parts sometime soon, it would be awesome to have that bike on the road this summer at some point.

but then, i have so many project sitting up here..
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sparkle butt maxi

a couple weeks ago i got sparkle but to sac thanks to my buddy ryan. it’s been super nice on the weekends lately and i’ve gotten to go out on a couple rides. this is such a fun bike!
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i think i’ll probably be out on it again this weekend, i’ll see if i can’t setup my gopro and get some fun video.

i really wish i could capture the color on this thing, it’s so rad.
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this bike is doug’s west coast rally bike now, and after all the trouble he had with the laguna i’m going to keep riding it now and again to make sure it’s in great shape for him the next time he’s here.

oh, and sorry about not updating this as often as i was for a while there. i’ve been working on dirty and a few other bikes, taking pictures for big updates and stuff, i just haven’t posted anything in a bit.
i do upload pictures a bunch to my instagram, though. follow me there if you want more stuff more often!

prototype atomic ZA50 pucks

atomic mopeds and sf moped mechanic andy has got these new 2 speed pucks he’s wanting to prototype, so i’m letting him throw a set in sparkle butt to see how it goes. they are harder than the standard atomic pucks and supposed to be more durable for big boy kitted ZAs.

andy dropping the oil
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these are a set of unfinished prototypes, the completed ones have been flattened on the edges…
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…as seen here.
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i didn’t really get any pictures of the process, as i was working on a scooter on the other lift for first kick. here’s sparkle butt all buttoned up after, though.
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he plans to rip around on it some next week, and then hopefully i’ll be getting it to sacramento where it’ll be my little sac ripper. it’s doug’s rally bike, but i want to keep it fresh and make sure it’s not a pain in the ass for him like the laguna always was.

also, new shop toy awaiting a cart that should hopefully show up any day now
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super stoked!

L’s maxi pipe coat rack

a few years ago L wanted a coat rack for our place, rather than buy one i figured i would make one. i was still in sacramento at the time working on mopeds for people at the motomatic warehouse and had a couple maxi pipes laying around, so i figured i’d go for it. with some scrounging i found a dented rim and a super shark-toothed rear maxi sprocket and a random header. after some work, this is what i came up with.
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i used three headers for the hooks and welded plugs in the ends to cap them off.
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for the bottom i cut the dented rim into sections and dressed the ends so they weren’t rough or snaggy, and ground the teeth on the sprocket to be back to more or less normal sprocket tooth shaped (but also not sharp or snaggy) and welded it all together.
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the whole thing was cleaned with degreaser and soap and water, but deep down inside the thing there’s still some 30 year old carbon that lingers. i was going to cap the ends of the exhaust pipes if the thing was stinky, but it’s totally not so i didn’t bother.
i’ve always meant to get pictures of it but it’s had stuff hanging on it since the day i brought it home and never had a chance to get any, our move last weekend finally gave me a chance.

some more mini magnum

so last time i had the magnum on my lift, i got the forks “kinda” on. i needed to work out a spacer for the headset nut and some spacers for the front wheel.
i was also planning on flipping the fork legs (left to right and right to left) to run the front wheel the right way around, but really, there’s no need for that with snowflake rims. it all depends on if i decide to use the speedo or not, as the speedo drive will run backwards with the wheel on backwards. i kinda do want to use the stock speedo, it’s got the actual miles of bike on it and it would be rad to run it, so we’ll see.
i also discovered one of the ball bearings had fallen out of the bottom cup upon assembly, so i pulled the fork apart again real quick to sick it back in there.
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after searching high and low for a spacer, i decided to just cut the top off the headset nut and run it upside down.
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i didn’t get a picture of my wheel spacers, but they aren’t anything exciting-just some washers that fit nice.

i decided to pull the side covers off to have a look at everything. plus i wanted to pull the wiring harness out. it’s not the cleanest thing, but everything’s in great shape!
i think i might replace the 12mm intake and carb with a 15mm intake and carb, but probably not right away.
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the oil fill plug is still nice and rubbery! that’s rare to find on a za these days it seems.
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if anyone needs a stock magnum wiring harness, including bar and brake light switches, i’ve got one for ya!
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a dark poopy picture. i need a camera!
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mini magnum!

since i’m waiting on figuring out parts for the sr250, last night i pulled down L’s magnum to start with the minification.
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i picked up a set of maxi length magnum ebrs and a set of maxi length shocks and started tearing into it.
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the shocks went on real easy, of course. the ones i grabbed are rad because they have 10mm and 8mm inserts for the mounting hardware, they came with the 10mm installed but i swapped them out for the 8.
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i’ve never pulled a pair of these magnum hydro forks apart before, they are great! the best quality fork i’ve seen come on a moped. i was going to try and sell them off, but i may hold on to them.
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the new forks went on super easy. i pickle forked the inner bearing race off the stock triple tree and installed it on the ebrs. it was a nice and tight fit, no need for a spacer!
i was also stoked to see the stock fork covers/headlight ears fit right onto the new fork! the up and down spacing isn’t perfect, but i can make it work with a little trying.
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i also threw on the pair of $16 bikemaster bars i had originally planned to put on the sr. i like them on the magnum though, so they may stay! i’ll cut them down, of course.

now it’s just a little guy! those 300mm shox might be a bit too small. maybe i’ll grab some 320s and try them out.
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as you can see, the rear fender is kinda weird to look at now that the wheel’s all up in it’s face. i have a couple ideas as to how to deal with that. i’d rather not trim the original fender, so i may end up removing it all together. we’ll see!

now i’m left with this rad bench-side cup holder. if anyone needs/wants a rubber magnum dash in great shape, let me know! same goes for the forks and fender, as i’m not quite 100% on keeping them just yet.
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next is to simplify the wiring, vinegar the tank, clean the carb and oil injector, a little mini tune including a new chain and cables, and to get the darn thing running!


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