84 recombobulated
 

Putting the 84 engine back together again with the included new and old parts.

New piston and cylinder + gaskets.

Also discovered this engine case has seen JB in its past before...possible chain loose/snap and case damage.

I cleaned it back and applied a fresh layer of JB weld...

Did all the timing and cam chain tensioner stuff...not that hard, just fiddly.

applied a smear of gasket sealer on the case side...cover side clean mating surface to paper gasket.

Grey clouds rolling in...so got it all closed up before humidity gets in...

Low High Lever
 

The 84 Hi lo transfer lever was a fraction of its former self and also put up a fight coming out of the cover...

the 81 will be replacing it after some clean and paint, then the transfer box can be reinstalled.

Most of seals seemed ok, even though I have a new seal kit nothing indicated to me that the original installed seals might be bad...so i just cleaned them and applied silicone grease...Some original cover gaskets looked ok too with a smear of sealer sealing the deal...

Just the timing advance CDI springs on wait...

Transfer box Assembled
 

The Hi/Lo transfer box re assembled.

Nice confirming actuation.

Also the 81 Cylinder head has been soaking in the vinegar bucket for about a week so it was about time to see if it would free up.

I used an M7 fine thread tap in a drill to bite into the dowel and shock spin the dowel out of the rocker arms...

Which worked...

With those out of the way i could remove the valve springs and see if the valves could move, or if they were stuck in the guides...

penetrating fluid and lots of little taps with a little hammer and both valves did come out.

Suffice to say after a clean up other than some pitting on the valve springs and a well used intake valve all parts seem usable.

Nice work! Like the orange range selector switch too.

more orange in store...

Rust removal and treatment
 

With a new set of wire wheel brushes and some industrial cola (phosphoric acid) Rust converter...

Made an effort on the 84 CT110 frame...

Mostly because I still have the welder spooled with mild steel so decided to use it now before switching to stainless steel on the van exhaust.

So needed the frame prepped for patch welding.

Found a couple of 40 old year Japanese weld 'quality' in the nether regions. Must have been a Monday or Friday.

The rust converter just makes surface rust inert (turns black) but it needs descaling to penetrate.

Got the 2 main rear fender patches zapped in enough to suggest solid metal where there wasn't any before.

Very thin material elsewhere on the fender so thinking it'll be a JB weld and body filler situation.

Still have a couple of inner fender patches to go but not bad for a first sheet metal zap and tap.

More Rear Guard.
 

A little more progress on the 84 rear mud guard.

cut a couple more 81 sacrifice patches to restore integrity on the 84.

then ran out of mig wire...

JB welded inner guard
 

So got the JB weld out and with a bit of masking tape as backing filled in the pitting and sieve holes...

after a next day cure pulled off the tape for a very nice outer surface...

then put the frame next to my other resting lounge ornament Honda project.

Unseamingly
 

With the main bike out of action for awhile felt like a good time to work on the 84 lounge ornament..


Wanted to get the welding out of the way and zip up any left over patch works...


Then opted to weld the seams to prevent any further/potential moisture ingress and inner layer corrosion from happening...the main area this occurred is on the battery box access side..


So more solid now than factory.



So the plan is to de-seam and fill/sand the multi layer chassis into a sleek CT110.


then get prepared for the rattle can spray booth...

Springs for CDI
 

The aliexpress springs arrived to replace the rusted out original timing advance tension springs...


Seems I was out by 0.1mm on gauge so they are a bit slack...however they are a match in every other aspect.


I honestly suspect this was the original fault that led down the previous owners rebuild escapade and the rabbit hole down the path of the snapped head stud...


Well I replaced the springs and the CDI snaps back so will see if the tension is enough...


But under the engine case the was a wet oil patch so I have an oil leak...

Look for the oil weep...
 

Oil appeared to be coming from the clutch cover gasket...


So got the impact screw driver out and removed the wallowed out factory case screws....


with that out of the way the internals looked good... the original gasket remained intact on the engine case side...So I Opted not to attempt to peel it off and get access to the pull out mesh screen...


Some shmutz in the bottom of the case but nothing i'm concerned about...


Looked at the kick lever seal and it was munted....So went to look at the gasket/seal parts bin....and....no....replacement...kick lever case seal...


Hmmmm.....OK now I realize why it leaks and why there is no replacement seal...because the munted seal is the new seal...ugh.


Ok repeat process on 81 swampy engine... Inspect internals...rough. missing semi auto clutch adjustment spring...But all there it seems...


the seal is ok but firmly set...the rest of cover is rough...


So went to Ebay and purchased another ct110 seal kit...


Lesson is...always confirm and have the right part in hand before trying to replace it when possible.

Starting to look around for one of these, minus engine. I ran across a Hensim 110 quad for free. The plastics are shot and the frame is rusted out from sitting outdoors, but the engine has almost no hours on it. The 110 has no reverse. It would be the perfect donor motor.

I've been searching for roached pitbikes/pitbike engines on FB marketplace as a donor for the rolling 2011 frame I have tucked away. But I might just go with a fresh crate lifan 125cc from Ebay when funds allow it.



It'd be nice not to do a top end rebuild everytime I try to build a new bike for a change...

CT Carburetors
 

Got the new kick lever shaft case seal but I don't want to risk more back strain with regards to my current sciatica.


So refurbishing a working original carburetor seems feasible given I have 3 in disrepair...


the middle 1 was the 81...I did not use any parts from it...


I ended up mashing the other 2 together.


There was some questionable areas in regard to the previous owners...


But out of the all the parts I do believe i have something resembling a potentially functional carburetor.


Currently now sanding layers of body filler on the chassis...but not a lot to show for it yet as it just look like a dogs breakfast right now...

Kick Seal Replaced
 

Still managing sciatic back pain, but on the mend.

In no position to ride bikes as the chance of hitting any bump in the road spark fear into my lower spine.


However I can move around sub normally, which means I can attempt some tasks...


so decided to fix that kick lever shaft case seal.


Got a craft knife and carefully separated the original gasket form the case...
the filter screen could be removed and inspected...some fluff and specs but nothing dire.


all surfaces were cleaned and added a light smear of sealant on both sides of the gasket.


Using an appropriate sized socket tapped the seal home and seated with a rubber mallet.


All installed and nipped up but resting on side overnight before testing if the oil will weep again...