1985 Honda elite 150 build thread.

[MICRider]

Originally Posted by katoranger

I only have a small compressor and it does not do well with the air impact. This will be alot easier than dragging out everything for one nut.

Yup, the electrics work great! My old boss had one and he used it for everything! Works great for countershaft sprockets and such too

[SpudRider]

Originally Posted by katoranger

Spud, on sale at harbor freight for $49.99.


Should make variator, clutch and wheel removal much easier.

Thanks for the tip, Allen! If I can use a 20% off coupon, I just might pick up one of those tools!

Spud

[katoranger]

It even came with a set of spare brushes.

[katoranger]

Well, looks like I will down for a couple weeks again. Too hot to ride anyway. I would rather be cold.

Been having problems with taking off. Like it is stuck in high gear. Found today that the clutch pulley was sticking and staying in just the high setting.

Also broke the throttle cable again. This time in the drive way. Must have been the original honda part.

The $20 scrappy dog belt is getting alittle worn too. About 2700 miles on this one I think. That may be all they are good for. I have a new one ready to go.


Since I am down and need to order parts. It will time to do some cleaning and fix the oil leak on the final drive.
Degreaser at work.


I order a new throttle cable, belt cover gasket, final drive gasket and seal, two more exhaust gaskets, and a final drive oil drain plug gasket. All OEM honda. $78 worth.

While I was in there I repacked the variator pulley rollers in grease. Already seeing some flat spots on them. I originally tried lubing them with just alittle lithium grease. It is ready for reassembly.

Called Bruce. He is going to see if we can match up chinese pulleys to fit. Much more parts available and cheaper tuning.

My next step is a vernier caliper.

Driven clutch pulley in pieces on the bench. Scooter in pieces on the driveway.

Get your popcorn and stay tuned.

[SpudRider]

I'm sorry to hear you scooter is down for repairs, Allen. :( I hope Bruce can find some Chinese parts that are compatible with your Honda scooter. My popcorn is popping, and I await your further updates.

Spud

[Weldangrind]

I knew you'd move towards tuning eventually.

Popcorn popping and ice cold adult beverages standing by.

[katoranger]

I think I may have the clutch covered. I bought myself a digital caliper to take some measurements with today too.

Scrappy dog has a variator that looks correct, but I would like to make sure first.

[katoranger]

New tool.

Much cleaner housing.

Variator shaft

Clutch shaft

Honda part on left and chinese part on right. The outer bearing on the chinese one is too large and the clutch shoes are smaller. If I can swap the bearing with the honda part I can use the origianal honda shoes and clutch bell with the chinese pulley.

My variator is 4.5 inches in diameter and has a 17mm shaft opening. The drive face has 21 splines on a 16mm opening.

Clutch shoes.

Original honda parts.

[katoranger]

Time for the some measurements.






I think that I see a circlip inside the driven pulley. This must be how it comes apart.

[Weldangrind]

Originally Posted by katoranger

Honda part on left and chinese part on right. The outer bearing on the chinese one is too large and the clutch shoes are smaller. If I can swap the bearing with the honda part I can use the origianal honda shoes and clutch bell with the chinese pulley.

If you can swap the Honda bearing into the China clutch, why not use the China friction material and bell?

Also, Chips Ahoy are two for $4.00. Time to stock up.

[katoranger]

If I can figure out how to get the thing apart that is what I want to do.

The chinese clutch looks like it may open up a couple more mm too. This should allow the belt to ride lower and give alittle more top end.

Anyway. I was able to get the honda clutch working. Sprayed some JB lube in there and it looks like it may have been rusty inside. I cleaned out a bunch of rust and now it slides nice again. Maybe this will buy me some time while I research more parts.

I don't know how to remove the part they call a seal collar. Looks like it is a friction fit. Under it is some pins that hold things together. Also need a long circlip pliers to remove the clip inside.

The GY6 clutch is promising though.

Got my cookies already.

[katoranger]

Maybe I can change the final drive shaft to a GY6 style. :idea:

http://cgi.ebay.com/ebaymotors/GY6-E...#ht_3471wt_732

[SpudRider]

I wish the Chinese hadn't made little changes to the parts. :roll: I'm pretty lucky that the engine in my Zongshen 200GY-2 is a faithful copy of a Yamaha engine.

Spud

[Weldangrind]

Originally Posted by katoranger

Maybe I can change the final drive shaft to a GY6 style. :idea:

http://cgi.ebay.com/ebaymotors/GY6-E...#ht_3471wt_732

That's kinda what I was thinking. Mr. Reveeen would likely know.

[humanbeing]

For the old REAL thingy:
http://item.taobao.com/item.htm?id=10309191353 |http://item.taobao.com/item.htm?id=7450525521
For the clone --SYM etc (6902 bearing!!!) http://item.taobao.com/item.htm?id=4986555161
http://www.cojp.com.cn/ is one these parts supplier