Ghetto rigged rebuild.

#1
First time poster, but I've been lurking on this forum a while, lots of really nice bikes/projects here.

Recently picked up a bike off of craigslist, (it's my first mini bike) and probably paid a bit too much for it. I liked the size of the frame but I'm not exactly sure what make it is, possibly a china knockoff?

Anyways I purchased it in non running condition, the past owner must have crashed it as the bolts holding the carb in place were broken as well as the pull start being ripped off and nowhere to be found.

I immediately bought the $99 dollar chonda special from HF, and it's now running despite every other piece of the bike being in questionable condition.
The forks are held on with an undersized OD piece of all thread, the throttle lever is almost completely broken, both wheels are loose, clutch engagement does not seem very smooth etc etc.

I plan on fixing the head tube/fork play first, measured the ID of headtube to be .510" so I plan on just using a 1/2" bolt unless I find a way to mount some external bearings.

Future plans inlcude:
fixing the wheels/axles
new brake setup, possibly hydraulic disc
new clutch
change throttle linkage to grip style
new seat
weld in new brackets for mounting seat (currently there is only one :eek:ut:)
weld mount in for kickstand
and possibly fab up a small stainless exhaust pipe (although I kind of like the quietness of the stock muffler)

Any feedback or tips/ideas would be GREATLY appreciated.
I understand this is not the forum for questions (so if my thread is out of line feel free to move it to the correct section), but I'd like to post my progress and get feedback from some of the more experienced guys.


 
#5
If your going to cut the steering neck tube off and redo it, it should have more rake added to it.That will make the bike a lot better handling and easier to ride.You could stretch the frame forward some more too.
 
#6
Finally got back to working on this.
Waiting on a big order of parts to get here.

Started stripping the paint off the frame, and also cut the scrub brake setup off as well as the right side footpeg (was undersize, rest of the tubing is 7/8" OD).

Couple pics, not the most exciting.
Found out the rear sprocket is Al when I took everything apart so I stripped the paint off of it and tried to clean it up. It is the only part I will be reusing aside from the frame/fork.





Also did a bit of GTAW (not pictured) to build up some sections of the frame that had been gouged out by a previous owner.
 
#7
Haven't done anymore work yet, but I was excited to get a large shipment of parts.
Extremely happy with the quality of the brake kit I purchased (made in USA), machined caliper and the fitment of everything is really tight. Much better quality than I was expecting for a mini bike brake kit. :scooter:
I'm also very happy with the quality of the seat, the wood has threaded inserts to accept bolts rather than wood screws.




 
#8
Looks like Christmas time!! Those are some very nice looking parts. I've always liked the Azusa Tri Star wheels, and that is a very nice looking brake kit! Look forward to seeing it installed.:thumbsup:
I am a little curious what the 4 bolt keyed hub is for?
Matt
 
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#14
Its starting to take shape now!:thumbsup: I suppose it depends on what you want to spend. Powder coat would be more durable for sure, but I usually end up painting, as I can do it myself, and it doesn't cost much.

Matt
 
#15
Cut the old seat mount off and made two new ones for the new seat, hopefully get a chance to weld them on tomorrow after work.
I also installed the OldMiniBikes throttle linkage kit when I had the motor mounted to the frame, and it feels like an improvement over the stock linkage.
The company I ordered the brake kit from finally got back to me and sent out the lever and cable. :thumbsup:

 
#16
Looks great so far! Are you going to change the front rake of the bike like Rocco suggested? I also think it would help out with the ride and change the look too. Keep at it!!!!
 
#18
Looks great so far! Are you going to change the front rake of the bike like Rocco suggested? I also think it would help out with the ride and change the look too. Keep at it!!!!
I'm considering it. More rake should make it more stable at speed correct? In the brief time I rode the bike before tearing it apart it seemed to handle ok, but I don't have a lot of experience with riding other minis to relate to. Once I get everything assembled I will test it out and see what I think before I paint the frame.

Got the seat mounts and new foot pegs welded on today, also got a shipment of hardware and had QC perform an inspection.



 
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