1985 Honda elite 150 build thread. - Page 27

katoranger · 08-14-2011, 10:06 AM

Too bad they are in China. If I could find a US/Canadian supplier I would probably buy one.

katoranger · 08-16-2011, 10:35 PM

Scored me a spare exhaust tonight.
http://cgi.ebay.com/ebaymotors/ws/eB...#ht_2221wt_958

Weldangrind · 08-17-2011, 01:11 AM

Now the fun begins!

katoranger · 08-17-2011, 12:15 PM

The new exhaust looks to be in better shape. I think I will use my current one for the modifications.

I will probably need to jet the carb.

SpudRider · 08-17-2011, 01:09 PM

If you have time, please do take lots of photographs, Allen.

Spud

katoranger · 08-18-2011, 09:44 AM

Spd, I will take pic. There is not many modified elite 150s out there.

Yesterday I finally figured out how the clutch pulley comes competely apart.

This is the new GY6 one.
Part that I was unsure about is what is called the seal collar.

I placed it in the vise and then gently put a pipe wrench on it.

The seal collar is held in place with two o-rings. Its purpose is to hold grease in and also 3 pins that limit the slide function.

This is the stock honda part. You can see why mine was not sliding too well.

I am going to clean, grease and reassemble the honda clutch. I think it will be okay why I am trying to build a custom GY6/honda hybrid clutch for later. I need some long c-cip pliers to reach the clip inside and remove the bearings.

I noticed one important difference other than bearing size. The GY6 pulley has the ability to open about 2-3mm more than the honda part. My thinking is that it would allow the belt to ride lower in the pully and give me alittle more top end.

For anyone thinking that a clutch reuild may be beyond their abilitys. It is easy. Just careful of the spring.

SpudRider · 08-18-2011, 02:11 PM

Thanks for posting the excellent photos, Allen!

Spud

katoranger · 08-18-2011, 03:50 PM

These pics are coming from my phone. Surprised at how large they are for only 2mp.

Anyway Brown delivered.

So I started getting the transmission ready to be resealed. The seal is easy. Have to scrape off the old gasket.

Suggestions on sealing the new gasket. Should I use a gasket sealer here?
More pics.

Clutch shaft. 160mm long. The rear portion that rides in the case in 12mm.

Maybe tomorrow I will be able to ride again.

Weldangrind · 08-19-2011, 12:50 AM

Three Bond or Loctite Gasket Eliminator are good choices.

I use Roloc (actually the fake version) on a die grinder to remove gaskets, although TurboT says to be careful to not remove aluminum in the process.

katoranger · 08-19-2011, 09:18 AM

Do you use the three bond with the gasket?

Weldangrind · 08-19-2011, 10:27 AM

No, it's what I use instead of a gasket, particularly when joining two case halves.

katoranger · 08-19-2011, 11:03 AM

Ok. I bought a new gasket from honda and put it together, but for future reference I will just get the three bond.

It should be sealed up now. New gasket and new seal. Also new copper gasket for the drain plug.

Next step is to get the clutch back together. Then I need to put the throttle cable on. Muffler on its way from AZ. I am going to run the new one while I determine how best to mod the old one.

SpudRider · 08-19-2011, 11:44 AM

Once the clutch is reassembled, are you ready to ride again?

Spud

katoranger · 08-19-2011, 01:53 PM

I thought so. I got it all back together. Clutch nice and clean I repacked with grease. It was nasty. Variator repacked in grease. New gasket on the pulley cover. New full synthetic gear oil.

Then I lubed and installed the new throttle cable. Works very nice.

Started it up. Noticed my LED brake light flashing. :?

Front brake lever loose. Cable stuck. :x

I have it moving, but it is very stiff. Hanging now with carb cleaner, but I am not hopeful.

Found a new OEM cable on ebay. Hopefully it only takes a few days. Scooter has been down for two weeks already.

This again was one of the original issues when purchased. I lubed it and it had been fine.

The good. CVT has never felt this smooth.

SpudRider · 08-20-2011, 01:53 AM

Fixing the CVT was the most important task.

I hope your new cable arrives soon, Allen.

Spud

08-17-2011, 01:11 AM	#393
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Now the fun begins! __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

08-17-2011, 01:09 PM	#395
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	If you have time, please do take lots of photographs, Allen. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

08-18-2011, 02:11 PM	#397
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Thanks for posting the excellent photos, Allen! Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

08-19-2011, 12:50 AM	#399
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Three Bond or Loctite Gasket Eliminator are good choices. I use Roloc (actually the fake version) on a die grinder to remove gaskets, although TurboT says to be careful to not remove aluminum in the process. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

08-19-2011, 10:27 AM	#401
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	No, it's what I use instead of a gasket, particularly when joining two case halves. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

08-14-2011, 10:06 AM	#391
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Too bad they are in China. If I could find a US/Canadian supplier I would probably buy one.
	0

08-16-2011, 10:35 PM	#392
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Scored me a spare exhaust tonight. http://cgi.ebay.com/ebaymotors/ws/eB...#ht_2221wt_958
	0

08-17-2011, 12:15 PM	#394
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	The new exhaust looks to be in better shape. I think I will use my current one for the modifications. I will probably need to jet the carb.
	0

08-18-2011, 09:44 AM	#396
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Spd, I will take pic. There is not many modified elite 150s out there. Yesterday I finally figured out how the clutch pulley comes competely apart. This is the new GY6 one. Part that I was unsure about is what is called the seal collar. I placed it in the vise and then gently put a pipe wrench on it. The seal collar is held in place with two o-rings. Its purpose is to hold grease in and also 3 pins that limit the slide function. This is the stock honda part. You can see why mine was not sliding too well. I am going to clean, grease and reassemble the honda clutch. I think it will be okay why I am trying to build a custom GY6/honda hybrid clutch for later. I need some long c-cip pliers to reach the clip inside and remove the bearings. I noticed one important difference other than bearing size. The GY6 pulley has the ability to open about 2-3mm more than the honda part. My thinking is that it would allow the belt to ride lower in the pully and give me alittle more top end. For anyone thinking that a clutch reuild may be beyond their abilitys. It is easy. Just careful of the spring.
	0

08-18-2011, 03:50 PM	#398
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	These pics are coming from my phone. Surprised at how large they are for only 2mp. Anyway Brown delivered. So I started getting the transmission ready to be resealed. The seal is easy. Have to scrape off the old gasket. Suggestions on sealing the new gasket. Should I use a gasket sealer here? More pics. Clutch shaft. 160mm long. The rear portion that rides in the case in 12mm. Maybe tomorrow I will be able to ride again.
	0

08-19-2011, 09:18 AM	#400
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Do you use the three bond with the gasket?
	0

08-19-2011, 11:03 AM	#402
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Ok. I bought a new gasket from honda and put it together, but for future reference I will just get the three bond. It should be sealed up now. New gasket and new seal. Also new copper gasket for the drain plug. Next step is to get the clutch back together. Then I need to put the throttle cable on. Muffler on its way from AZ. I am going to run the new one while I determine how best to mod the old one.
	0

08-19-2011, 11:44 AM	#403
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Once the clutch is reassembled, are you ready to ride again? Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

08-19-2011, 01:53 PM	#404
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I thought so. I got it all back together. Clutch nice and clean I repacked with grease. It was nasty. Variator repacked in grease. New gasket on the pulley cover. New full synthetic gear oil. Then I lubed and installed the new throttle cable. Works very nice. Started it up. Noticed my LED brake light flashing. :? Front brake lever loose. Cable stuck. :x I have it moving, but it is very stiff. Hanging now with carb cleaner, but I am not hopeful. Found a new OEM cable on ebay. Hopefully it only takes a few days. Scooter has been down for two weeks already. This again was one of the original issues when purchased. I lubed it and it had been fine. The good. CVT has never felt this smooth.
	0

08-20-2011, 01:53 AM	#405
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Fixing the CVT was the most important task. I hope your new cable arrives soon, Allen. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0