It all starts here

This is the colour scheme I am hoping to be using. Its a shame it won't go as well.

Project Suzuki GT50 79’ Restore and Preserve

Today 1 Feb 2011 after asking mates on UKMOC I received the call of a moped for sale that had been stuck in a shed for 9 years. I checked out the pictures he sent me and although it looked all there, it still looked a mess with lots of work and money to spend so was reluctant on going to the first price guide of £300-400 .

I was then surprised that he actually would take £200 and that it would else be e-bayed. To which I said a big positive YES. Whichever way I looked at it I could probably sell it for more if I had too.

The pictures do show the condition to be filthy and covered in dust and there are areas of rust that look too bad to be able to save them such as handlebars and rear shock absorbers. There is also a dent in the top of the tank we have since seen but my thoughts are it maybe able to pulled out if not a full respray would look better anyway. Apparently before storage it was covered in oil to protect the metal but no doubt there will be some damage.

So the project will begin in a couple of weekends when I pick it up from Devizes from Rally.

Been on the internet looking around for replacement bits in advance and found some reasonable prices to which I can not worry. My main concern will be the engine as in do I take it apart and replace piston and rings. Not expensive to do luckily.

From the photo’s I’m thinking this is a list of parts to change

Handlebars

Rear shock absorbers

Front and rear tyres

I have found some info about this type of bike.

Suzuki RG50/GT50/ZR50/X1 brochures   1977 Suzuki year code: B 1977 RG50 sales brochure from Japan. Click to enlarge.I found this on some Japanese website. I'm not sure about the year, I'd guess it is from 1977. Wire wheels and a single passenger seat. Mechanical disc brake at the front. The RG50E with cast alloy wheels was not presented until 1979. 1977—1978 RG50 specifications (Japan)Overall Length: 1 815 mm (71.5 in) Overall Width: 685 mm (27.0 in) Overall Height: 955 mm (37.6 in) Wheelbase: 1 170 mm (46.0 in) Dry Weight: 76 kg (167 lbs) Engine type: Air-cooled 49 cc 2-stroke, reed valve. Bore x stroke: 41,0 x 37.8 mm Compression ratio: 7,2:1 Maximum power output: 6,3 hp/ 8.500 rpm Maximum torque: 0,53kg-m/ 8.000 rpm Starter system: Kick starter Clutch type: Wet multi-plate Transmission type: 5-speed constant mesh Primary drive: chain Frame type: steel pipe Front suspension: Telescopic, oil dampened Rear suspension: Swinging arm, oil dampened Front Tyre: 2.50-17 Rear Tyre: 2.75-17 Wheel type: pressed steel, wire Retail price, Japan 1978: 119,000 Yen 1979 Suzuki year code: N 1979 GT50P sales brochure from Holland (two pages). Click to enlarge. This Dutch model with wire wheels and single passenger seat looks is the same bike as the Japanese RG50 but with adifferent name. Also known as the ZR50. 1979 GT50P Special sales brochure from Holland (two pages). Click to enlarge. The ”special” model of the Dutch GT50 is the same bike as RG50E, ZR50 or X1 with alloy cast wheels and a twin passenger seat. 1979 RG50E specifications (Japan) Overall Length: 1 815 mm (71.5 in) Overall Width: 685 mm (27.0 in) Overall Height: 955 mm (37.6 in) Wheelbase: 1 170 mm (46.0 in) Dry Weight: 72 kg (159 lbs) Engine type: Air-cooled 49 cc 2-stroke, reed valve. Bore x stroke: 41,0 x 37.8 mm Compression ratio: 7,2:1 Maximum power output: 6,3 hp/ 8.500 rpm Maximum torque: 0,53 kg-m/ 8.000 rpm Starter system: Kick starter Clutch type: Wet multi-plate Transmission type: 5-speed constant mesh Primary drive: chain Frame type: steel pipe Front suspension: Telescopic, oil dampened Rear suspension: Swinging arm, oil dampened Front Tyre: 2.50-17 Rear Tyre: 2.75-17 Wheel type: start type cast wheels Retail price, Japan 1979: 133,000 Yen 1979 GT50P and GT50P Special specifications (the Netherlands) Ground clearance: 175 mm (6.9 in) Dry weight: 71 kg (156 lbs) Engine type: Air-cooled two-stroke, single cylinderCylinder displacement: 49 cc Bore x stroke: 41,0 x 37,8 mm (1.614 x 1.488 in) Lubrication: separate oil injection Carburetor: Mikuni VM12SH Head light: 15 W Rear light: 8 W Stop light: 15W Battery type: 6V 4Ah Starter system: Kick starter Clutch type: Wet multi-plate Transmission type: 4-speed constant mesh Primary drive: chain Pedals!!! Frame type: steel pipe Front suspension: Telescopic, oil dampened Rear suspension: Swinging arm, oil dampened Front brake: Single disc, diameter 220 mm (7.7 in.) Rear brake: Internal expanding drum brake, diameter 110 mm (4.3 in.) Front Tyre: 2.50-17 Rear Tyre: 2.75-17 Fuel tank capacity: 8,5 liter Reserve: 2,4 liter

The original look with Alloys. Sold as RG50

This one looks nice. Seats better and no rear footrests.

 Day 1

Saturday 12th February 2011
The day came quickly when I had to drive to Wiltshire to Rallys house to pick her up. I left at 7.30 from Kent and the journey took just over 2 hours. I arrived to see this.

Before I left we managed to Blow out the dent in the fuel tank with an air line. There remains a tiny ' Dink ' but as a respray is happening it will not matter. We also tried to start her but carb was later found to be full off gunk but we were pleased to see a good spark.
The journey home in the back of the Astra was around 2.5 hours and the fastest the bike would ever travel. The fumes from the carb were not nice.

                                                        

Once home I easily dragged her out of the car handlebar less of course and how light she is compared to my lightish Ducati Monster. I took some daylight photo's of before for posterity and to show how bad condition she is relatively. Of course its all fixable or else I wouldn't have bought her. 

 The rear shocks are going in the bin as I have brand new replacements for £38 inc post  for a pair.

 
The exhaust will probably be binned too as is well past it. A new Allspeed system may be purchased. You can see the rusty swingarm but its not bad at all

 Engine came out easily. Only problem is front lug is broken on the casting. The head and barrel will also be repainted as enging casings. The side shown is all plastic for the record.

 The rear mudguard was removed and just 2 bolts sadly sheared but will not be a problem as all bolts are to be replaced with stainless steel ones.

 The tank removed with just one bolt and at least the big dent has now gone but its still got plenty of scratches.

The frame remained  along with the forks on Day 1. I feel I had a good day with no big dramas.

The verdict is that the bike is all there and generally good. The worrys are the wheels and exhaust. I am thinking of getting smaller new rims and getting new spokes and relacing them from 18" down to 17". Cant see this being a problem as AP50 and Fs1e are 17".

Time spent driving and picking up 7 hours.

Time spent on bike 4 hours

Day 2

Sunday 13th February 2011

I never started until near 1pm but the front forks were removed firstly. Condition good but lowers need a rub down and laquer or repaint.

Wiring loom was kept together attached to headlamp. Was cleaned and found to be in very good order, All cables and connectors are very good.

The swingarm was a pig to get the pivot bolt out. After a good soak I did manage to drift the bolt out and only damage was to the nut.

All the boxed parts were generally cleaned today of road dirt and grease and put into a fresh bag or box for work to be done or ok.

The clocks were separated so I could get the bracket for painting.

Oil tank was in a dirty state but is now clean and fairly good order.

The seat was looked at and needs a recover to be good. The split is bad enough not to bother repairing. I removed the seat trim for painting. One of the bolt holding the grab strap broke but can fit a bolt through later. Rear seat cowel is in good order but repainting with new colours.

Tank was inspected and cleaned generally. It will be filled and resprayed. The tank filler cap will be replaced due to chroming bad.

The airfilter box was cleaned and alls good there. I will need a new filter as this ones falling apart and sodden with oil.

The side panels are in good order after a good degrease and clean. The decals are good but wil replace both as one was slightly faded and may also spray paint some design on the too.

Wheels were looked at after I removed the awful tyres. The rear is worse than the front but really need both replacing for new or better. Possibly 17" is the way to go down from 18".

Front brake caliper needs the rubber cover grommet and a paint refurb. Have new brake pads for it. Cable may be replaced.

Indicators are generally ok but one has body damage and another is suspect. Replace 2 or full set maybe.

Rear lamp is ok but needs some work like body replated and lens needs a seal.

Rear mudguard cleaned up very well and pleased with that.

Engine still has not been touched but is generally clean.

Time spent 4 hours

Day 3

Tuesday 15th Feb 2011

This evening Im not sure whether its a disaster or a good thing I found. I decided to remove the swingarm bushes so it could go for powdercoat next week. As i was trying to extract them the swingarm started to bend in on itself. After I cleaned all the grease and crap off I saw it has had some damage possibly a knock and theres a crack. Not a bad one that cannot be fixed but something that Im glad I noticed. I managed to re straighten it and cleaned it all up. I will make 2 new strengthening plates and get them welded on.

I attacked the rear wheel with a wire brush and the pittings not that bad that it cant be sorted with either rechroming treatment or powdercoat but I have seen on ebay a complete suzuki zr50s in need of work which I may get and swap a resell good bit if less then £200. Could use the wheels  ( alloys ), exhaust and tyres and other bits.

i also polished up  almost one fork leg and came out good.

Time Spent 2 hrs

Wednesday 16th Feb 2011

I didn't spend much time tonight other than cleaning the frame down with wire brush and degreasent. A bit of attention to detail as the frame needs to look good as it wont now be powdercoated. I also spent an hour on the engine wire brushing the head and barrel which will be re-painted. Its in pretty good shape and its lucky to be small and light to assist cleaning.
Time spent 2 hrs

Friday 18th Feb 2011

Tonight I painted the frame with rust preventer and primer. A trip to halfords on way home to get the paint. Hammerite Smooth in Satin Black was the preferred colour. I also painted the first coat of the top and bottom yokes.
Tomorrow I will paint the frame. Hope its warm.
I also clean the side engine cover which is plastic. Now clean inside and out and will be painted as the paint is patchy colour and slightly scuffed.

Time spent 2 hrs
Money spent on 2 cans of paint and Rust preventer and wet and dry. £31.80

Saturday 19th Feb 2011
Today I went and sprayed the frame satin black. It was an awful day and not the best conditions to do it as was raining outside and quite damp. I did it at my mum's garage so no light or power. I had a few problems with the frame being basically too cold. It looks ok but I am going to rub a couple of minor runs down and overspray them. I also second coated the top and bottom yoke.
Other than that I went back home to my garage and cleaned up and repainted brake hub anchor tube,  battery holder and rear mudguard frame mount.

Time spent 3.5 hrs
Money spent 1 can hammerite black £10.49

Sunday 20th Feb 2011
Today a few more bits done. Frame bought back to home and needs more paintwork doing. Not always easy to spray upside down and the runs need rubbing down. Going to let it go off a bit more first. The main stand was degreased and cleaned and 2 coats of paint. The footrest hanger was degreased and 2 coat applied. The brake tie rod, brake pedal, top and bottom yoke and rear mudguard mount were baked in the oven on a moderate 100 degree heat for 30 mins. I cleaned and straightened the headlamp mounts and primed them to stop rusting. One was slightly bent but hardly noticeable.
Handlebars clamps painted black. Dismantled the rear footrests for repainting or replating.
I have come to a point where what I wanted to do may not happen for a while. Its going to look good but not as good as I had wanted. The exhaust is awful and nothing will make it better and the wheels will have to stay as they are unless a set come along. I missed out on the other ebay suzuki zr50 X1 due to the guy pulling it 2 days before it ended so there went my 18" alloy wheels and black expansion style exhaust.
I will pst some finished pictures of parts later.
Time spent 3.5 hrs

22nd Feb 2011

Tonight I spent a couple more hours fettling and and cleaning. A bit of a result on the exhaust front is that I managed to get an almost mint Micron Chrome expansion chamber on the ebay. I wont get it until next week as my friend Rollo is picking it up and posting it to me. Its for a GP100 but should fit. Same clamp size but 3mm larger bore. I also the seat cover coming so I removed the old one tonight. Seat is relatively good and foam to be fair is remarkably intact. At the front its slightly rotted away but I will try and repair some how. I will repaint the base as it has patchy rust. The hooks are mostly there so hoping it will be ok. It has a trim which will clamp it anyhow but that needs a repaint.

The fork bottoms were rubbed down more and are nearly there. I really dont want to paint so more work needed but maybe mechanical. Once polished maybe laquered over.

The rear brake actuator rod was very rusty and nut was really tight. I rubbed down and is now shiney and bright and the nut turns pretty much by hand. I really want this replated and not painted.

The rear brake unit is now shiney and clean. Left the knackered fallen apart shoes in but this will polish nicely too.

The wheels I have to say Im in a quandry. I can go to 17" but really want to stay original. Seen some in Thailand but $70 and $70 post and need spokes too. Can I relacr the wheels ?  Probably yes. I attacked the spoked with WD40 and wire brush to see if I can live with them for a while. They are looking better for sure but will never be right. If I was to get new rims then the hubs will have to be polished or shotblasted.

I went over the main frame tonight too. Looking ok now. I will bring it back in a couple of days.

I pre-assembled the front forks to keep all the bits together as Im starting to need to know what bits are needing to be replaced. Bolts, bearings etc.

A few bits were baked in the oven tonight. Footrest hanger, battery cradle, centre stand and speedo rev counter mount.

I also got a new chainguard well secondhand off ebay. Its a GP100 metal one that should fit but may need modifying on mounts. As it metal thats ok and as it also has some slight rust it will be painted black like the original black plastic one. That one is junk as it has a split and a bracket is broken and it also looks like the chain has eaten it at some point.

Rear Mudguard support bracket

Rear Mudguard support bracket

Rear Brake tie rod

Rear Brake pedal

Rear Brake pedal

Rear Brake slightly polished

Restored but to be plated rear brake rod

Rear Brake with rod

Front forks

Front forks

Centre stand

Footrest Hangers

Speedo/Revcounter mount bracket

Battery Cradle

Pre assembled forks without gaiters

Seat without cover

Slight damage at front left

Slight damage at right front

Old seat cover

Time spent 2.5

Money spent £120 exhaust + post, seat cover £13, chainguard £8.95

Friday 4th march 2011
Well its been a week or so since last update. Things are well going ok !.
I had a problem last week with the wheels. Replacements were available from Thailand for around £120 plus I needed spokes. I could have and nearly did go down to 17" AP50 rims new with spokes for £77 but as much as I wanted to actually respoke them I would have had to have got them professionly balanced and 2 brand new tyres another £40-50 and upped the sprocket size no doubt.
I was almost going to then I spied an ebay breaker. ZR 50 18" alloys and forks and hydraulic front brake. Managed to get them for £100 delivered. Not yet got them but I will resell the forks for at least £50 and I have 2  18" rims and hubs and a brake caliper for sale for a GT50 or they can be used on a AP50 or FS1e too. They do need a good clean up but they will go well with my Sheene Heron Suzuki theme when painted Gold.
I also got on ebay a gasket set, a Yamaha fs1e fuel tap that doesn't fit. The thread is slightly finer than suzuki's. I think I have found one for mine. Its off a GN 125 and these types of tap are not common on Suzuki's. Just my luck I have such a rare beast. I also got a brand new brake rod all shiney for once again a fs1e which will fit for £6. The exhaust should arrive this weekend and will post some pics.
My seat cover does not fit as it should and won't be going on. I will find someone to make a pattern copy as I want the original look as much as possible.
The engine has been cleaned and the head was off yesterday. Came off easy with NO dodgy studs or nuts and was fairly clean. Just a tiny bit of carbonising.The bores are also fine but who knows until I start it. Doesn't seem to be any play and the bores were oiled by previous owner. Head will be shotblasted and barrel painted black. I took the clutch casing off to paint but will probably paint with it on. I wanted the Philips screw sizes to replace with Allen bolts. List is being compiled.
I started to rub down the Tank last night for an hour. It has a few scratches which rubbed out and just a tiny dent. I really just wanted to see if any bad rust. Its really good considering.
Im watching a brand new swing arm for a zr50 on ebay and hope I can win it as its just down the road from me. Ends tomorrow night. It will save me the bother of welding and straightening the other one up and then repaint it.
Tonight I gave the frame another couple of coats after rubbing some paint runs down on saturday. It really isn't the weather to spraypaint frames. Too cold.
Tonight I resorted some bits out and had a tidy up.
Want list is now less.
ZR swingarm
new clutch side switch unit and black lever
Rear sprocket hub mount
New chain and sprockets
Chain adjusters to suit either repaired GT or ZR swingarm
Front mudguard race or genuine
New footrest rubbers and new rears if possible
Handlebar grips
Battery
TS50 rear chainguard as GP100 one is crap and too long and cant be bothered to adapt.
New fuel cap

Sunday 7th March 2011
Well being at work this weekend I haven't done much. I did however miss out on that brand new swingarm and decided to go for a good bid. Last second I got outbid because my bid never made it but the winner paid a hefty price and delivery on top as I could pick it up.
There is a plus to it as I have now decided to get a GP100 swingarm that is 1.5" longer but this shoud be ok as you can see in the photos there is plenty of room. The only thing I have to watch is the shock absorber angle and height.  I could modify the swingarm by chopping and rewelding the pivot bushes or the shock mounts. But I also aim to repair the original swingarm too. If not just to sell. The GP100 swingarm also comes with a straighter tie rod and better rear footrests. He also has an axle and adjusters and these are also beefier than GT50 ones and the ones I have are poor. One is fair and the other is broken and cannot find a supplier as yet so I would have to make one and plate it.
The frame is back in the garage and looking better than the first attempt. Nice and black. Thi coming week I aim to start re- assembly of some parts. Lots of pics too.
Heres the wheels and forks I have got coming and the exhaust.

A very rare exhaust

Just a tiny dink

The ebay wheels tyres and forks.Inc Hydraulic brake and axle. Mudguard is binned. These will be repainted all gold as per Heron Suzuki

I hope this is the right fuel tap this time otherwise a new outlet on tank will be done.

Tuesday 8th March 2011
Another parcel arrived at my mum's today so I picked it up. A nicely packed  GP 100 Micron exhaust sent to me via Rollo ( Duncan) of the UKMOC. Thanks mate.
At first glance its very smart and in 1st class order. I did initially think it would be too big but I had to know in case I had to re-sell or modify god forbid. Only one way to find out. I put the frame on a base and plonked the engine back in loosely. The exhaust gasket supplie in a kit didn't actually fit in the groove on the barrel ???? , but the manifold /down pipe fitted ok. Just nipped up for now. I then slipped the expansion pipe on and it lined up with the swingarm bracket as per original. It technically fits. I will have to get an X5 or X7 rubber gasket sleeve to cover the join or else exhaust bandage. Its a bit longer than the original but its ok I think. Better than original for sure. What with maybe having a longer GP100 swingarm it should be ok.
I also got a brand new rear brake rod all Yamaha FS1e.
I put the tank on to see how it looks. Its slightly rubbed down to see the marks. The frame looks good I think. I can't wait to get the swingarm on and get the wheels to see the real change.
A few pics. Sorry about the messy garage.

The engine still has to be painted.

Paint has been rubbed down to reveal scratches and dinks. Only one small dent.

Time spent 4hrs

Friday 11th March 2011
Yesterday I got a very nice parcel. Some alloy wheels in need of a bit of elbow grease but all in good order. Didn't get to do anything with them until tonight.
I got the spare pair of forks today as the parcel was too big to send in one. I got home and took the wheels out back and gave them a good clean. They weren't badly pitted or corroded but needed a sand down with wet and dry. The gold paint was pretty good for around 25 to 30 years old but some of it was stained. I got a fine wire brush and gave the paint a brush. I am planning to paint all the wheel but will think about keeping the rims polished for a while as they are in good order.
The rims run true and bearings look good and well greased. I just need a sprocket hub now and hoping one will be in my free bits which I pick up tomorrow morning.
There was also a hydraulic caliper with it that looks in great order other than the reservoir has no fluid in it so it may work or maybe not. Its an alternative I want to use rather than the cable one.
The spare pair of forks will be cleaned up and possibly sold to recoup some money. I will also have a set of wire wheels to either refurb or sell on with the good hubs and brake caliper.
The dry assembly is going well and is almost complete. My only need is this swingarm and sprocket hub and better switchgear.
My only problem I have found is that the new exhaust won't quite fit between footrest hanger. I can easily modify it by cutting it and adding about 20mm to the length. I should also have a spare one tomorrow so can go back if needed. I will then have to lop a bit off the footrest bar.
I quite like working off the workmate but I think I will modify it to make it more secure. I also plan to use it when I do my Ducati 600ss.
Just still waiting for my fuel tank tap. I also need to order a race front mudguard. Just hope it has a similar radius. I also need to think about either recovering seat original copy or making it into or buying a race style seat.
Pics from today

Time spent approx 3hrs

Saturday 12th March 2011
Today I got up early to drive to Cambridge to bring back hopefully some useful parts for replacing some of my damaged bits. I set off at 07.50 and arrived at 08.05 thats 81 miles of easy  empty roads. I was too early so a brekkie was called for @ Mc D's. I got to Darrens ( UKMOC) at 09.00 to be greeted by a large box of bits, a frame and 2 wheels in fair condition. I didn't stay long as I wanted to get back to avoid the traffic and was home by 10.35.
As soon as I got home I checked the swingarm against the damaged one. Ooops! conclusion. NO it won't but yes technically it could be made too. Its 1" wider and 4" longer. It also uses a 12mm pivot bolt other than mine is 10mm.  No matter as it can be sold to fund some more bits as can some other parts.
I did manage to use a number of bits.
Rear sprocket and hub carrier
Brake tie rod (is fatter than mine)
Rear Brake hub (better than mine)
Switchgear possibly
Rear 2.75 tyre
Side stand
Headlamp brackets ( simpler)
Some nuts and bolts
I also could make up a standard set of Wire Wheels for spare or complete originality.
I also was able to use some metal from the footrest hanger which was fairly bent and damaged to modify mine to clear fatter exhaust.
I basically spent the afternoon cleaning and making sure I had the correct spacing for the wheel to fit into the original swingarm.
I have come to the conclusion that at some point a previous owner obviously lost a spacer and clamped the wheel in without, causing the bent arm and damage to shock mount and chain guard. It was approx 6- 8mm out.
I managed to strip down hydraulic brake lever and undone the 2 banjo's. The bleed nipple is to tight to undo yet so will soak a bit more.
Time spent 8 hrs and inc travel to Cambridge 3hrs

Sunday 13th March 2011
Today is the critical day in the rebuild. The swingarm has to be fixed as I have no other other than modifying one not meant for it. I never saw this as an impossibility but just a tedious job and being able to have a workshop available for me to use. Well lucky I have a great mate ( Scrapp's of UKMOC) who not only gave me use of a press and vise and grinder and tools, gave me his time and help on a sunday. He and I not only straightened the swingarm which was twisted, but modified it to use the newer adjusters. Good job as I cant find a replacement old type anywhere.
We bent the original adjuster lugs back flat and then filed open the gap to allow the bolts some clearance. We were then able to use a hydraulic press to flatten the bent metal. That was easy and looked good. I then opened it out to the correct gap and we measured the gap of complete axle and adjusters. This is because the spacers are now slightly to wide as before the never had a washer thickness inside. So I will turn on a lathe around 0.75mm off each side.
Now the hard bit. The re-strengthening of the brace. I got a piece of sheet steel and drew with my template the shape and cut it out with a grinder. Delicate and dangerous stuff eh !. It was tricky but successful. I clamped the piece on and finish filed it . Both sides down and the end and will be welded professionly.
I also got Scrapps to staraighten the bent headlight mount. He did it superb with his press.
I have also modified the footrest bar to allow the exhaust to clear as its now fatter. I still have to measure it before getting that welded but feel confident.

Pics to follow
Good day I think.
Time spent 4hrs

Sunday 20th March 2011
Been very busy and not had time to update. Just minor fettling during the week and I now have new switchgear. I got a brand new one for a GS 125 and just minor rewiring the connector block and job done. Ordered new stainless steel bolts/nuts/screws and washers too.
Saturday I picked up the new bolts and the repaired swingarm. It cost me £25 to get welded and for sure its good and strong. I did have to fettle the weld for presentation in a few places.
Sunday I got up early and down to mums to spray the swingarm. 2 good coats and a bake in the oven. Whilst waiting for paint to dry I fitted a lot of bits with the new bolts etc. My aim today was a rolling chassis at least. I refitted the front forks and also the centre stand. This would give me a chance to put on the floor. I had to refit the slightly dodgy cracked tyres and tubes so I could wheel it about.
In the afternoon the swingarm went back on. New shocks too. Nw for the wheel and spacers. Thats where the problem arose. Not enough taken off the spacers to allow it to all go inbetween the gap. I temporarily used washers just to get moving. Now for that exhaust. Yes it fits on the bike but it fouls in 2 or 3 places. This was a gamble and Im not now fitting it. It will be resold and my options are very limited. A brand new Allspeed can be made around £170 or I try to strip old exhaust and refurb or buy a smaller old second hand expansion of a 50cc and hope its dent free and not chromed for modifying.
So I know where Im going now at least. Right engine comes out and some paint is to be applied. I took the head off and then for the first time removed the barrel. Never seen a barrel with reed valve. The piston has a couple of minor scores so I may get new piston and rings as not expensive. I gave the barrel a bit more wire brushing underneath and a bit of a decoke. Then I applied 3 coats of black heatproof paint. The head is a bit filthy so thats going in the dishwasher. I may try some silver paint on that the same as the engine.
The engine I thouroughly cleaned top to bottom and masked it up ready for paint. I will do this painting this week.

I also rubbed down the tank and removed all the graphics. They were a sticky pain.

Time spent Sat/Sun 8hrs

Friday 25th March 2011

I have done some odds and sods during the week. Been buying the small bits and sadly selling the Micron Exhaust. But then I was lucky browseing ebay I came across an exhaust for a Suzuki OR50 which is the chopper style bike. Buy Now for £14.99. Bought it and it came today. It fits but it could do with a few tweaks. They must run these bike without rear footpegs as it fouls. Cut off or lengthen the front pipe and move bracket a bit. Really pleased with the look.

So what did I buy this week. New swinarm bolt and nut from a Suzuki dealer, Bates in Dartford, and some new shock dome nuts. I also got a new front brake lever and brake switch. Mystery now solved on that one. New piston and rings set which I fitted tonight. Good job as old one was scored and looks like a crack in it and one ring broke when taking it off. Thats all done and is together without gaskets for now so I could try the exhaust on.

No petrol tap as yet still.

No joy on seat cover but 2 places are ok. One is a friend who has offered.

Hydraulic brake and cable one have been resprayed black.

Looking foward to some good hours sorting some stuff over the weekend. Engine and gaskets fitted and new bolts.

Tuesday 24th May 2011

Its been a while since I last posted but have been busy doing other things along with odd moped bits.

So whats happened.

Another Micron purchased suitable other than header is for x1 ( flat fronted barrel GT is angled )

Seat cover has been made and very nice too Goldsmiths Upholstery of Ipswich

Seat base has been repaired and stronger. Needs painting.

Seat to be recovered in around a week as waiting for new spikestrip from ebay.

One wheel has be resprayed black. Not sure black or gold

OR50 exhaust is the right length to now fit. Fit new bracket and weld on.

Components are ready to go to platers when they get back to me.

Got my petrol tap from a local guy for £15 as new

New switchgear clutch unit got and rewired to suit GT50 electrics

All I need is

2 tyres 18" x 2.5" and tubes possibly good idea

2 x indicators or 4 if possible

battery 6 volt

front brake pads

throttle cable

clutch cable adjuster from GN125 or complete cable

Exhaust header to fit Micron exhaust

Tuesday 5th July
Got back my plating and cost me £30 for te 63 components. Now its time for the rebuild. After a break of doing a lot og UKMOC stuff I really want to crack on and get it built and ride it hopefully. Im hoping by end of July.
All the parts I put on now will be fitted properly.
Rear wheel has to be painted still and the black modified OR50 one has to have a repaint.
The wiring loom needs a bit of tape at front to tidy it up.
Its much likely just pics from now on with the odd comment.

August 15th 2011
So the latest update today. Have been on a spurt trying to get this thing moving by its own power this last weeks. I have repainted the wheels to a gold as the black looked too modern. The seat is now recovered and looking very nice. I still would like to build a solo racing seat at some point. I'm still hopeful of another seat cowel I can repaint I saw in an ebay buy.
This week I'm ordering the last parts I really need to get it ROAD LEGAL.
Brand NOS chainguard as the one from canada not come from daughter Kim yet.
GT fork dust covers so I dont have to use the gaiters.
Some clock lights as 4 don't work. At least I know the neutral light works.
A rear sprocket hub bolt and nut as only have 3 out of 4.
I have a ZR50 front plastic mudguard coming sometime gratis for a swap of some spare fork gaiters but I have found a brand new RD125 type one that looks the part so just checking on fitment across the forks.
Ahh the ignition switch saga. There is much dispute across the moped forum about GT50 ignition. I have had 3 of them and the one that fits identical is a TS one. Colours and pins exact. The early GT50 had an ignition switch clamped to bars and the idiot lights integrated in the dials. Mine has the 3 position switch with the park light too. Handy but you wouldn't leave it on for long.
Lights were an issue and I had to rewire the headlamp unit as the connections were somewhat dodgy. It all works now and everything is STUFFED inside that little candle headlight and works too.
So I had a week off work and got stuff bought and fitted. Four new indicators, a new  front brake cable which was a pig to fit, a new battery, a new air filter ( cone type ) as the stock front tube is solid and useless, and a new rear light.
Tyres also bought on the internet. I ended up going for 2.75 x 18" front and rear against the standard 2.50 which are hard to get in 18" form. I think I made a good choice with the Metzlers ME22 as they are rated in the moped forums. Got a good deal too as £62.00 a pair.
So the latest photos of it nearly together

I had an issue with the engine. A few weeks ago I got it started. I was well chuffed.The downside was it wouldn't run OFF CHOKE. A small video is here

 

After that it was full steam ahead as I had no doubts this was going to be a success.

I wanted to sort out this choke issue so I stripped the carb down again. It was still fairly grotty so another good clean was done. Put it back together and it ran but worse.

Off again and even though it looked ok I scrubbed and soaked in petrol and put back on. Success and she runs off choke and tbh doesn't need choke to start. Maybe a bad thing and maybe its running rich ?

I did a short run around the house and it was well fun. More power than I expected tbh but needs a tune up still

 

 

So the shopping list is getting to the end and hopefully the next blog post it will be road legal and taxed.