New Project(s)

Discussions and updates on your new bike, your new build, your wishes, wants and desires
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Rockburner
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Re: New Project(s)

Post by Rockburner »

Had an hour or two yesterday so tinkered with the Puch.



Definitely needing a new fuel tap....

Tank is currently full of citric acid to eat the rust and I'm going to wash some ACF50 round it afterwards to keep it from getting bad again while i sort out the carb. Should be fine, its a 2-smoke!

While tinkering i stripped the "air box" and discovered its still got the restrictor plate in. Will leave that until its fully working and then see if we want to unleash the full potential! :D

I also put the pressure tester on it just to see if there was any compression at all... 30psi. Not a lot, but its only a 50cc, so we'll see.... I want to at least try it with fuel in before i strip it any further.

Also ordered up some oil and ATF (for the gearbox) from Westway Oils, so, along with the carb repair kit and ultrasonic cleaner that are en-route, there is progress being made.


The JAPton is waiting for the ultrasonic as well, and I have a repair kit for the Monobloc ready and waiting, so looking forward to seeing if that makes a difference. I have also tinkered a bit with the valve gaps and i think they're better than they were!
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Re: New Project(s)

Post by Rockburner »

Emptied the citric acid from the Puch tank today, seems to have loosened a lot of crap! Washed the tank out as best I can, and there's an inline filter on the way with the new tap to catch anything left.

I also whipped off the exhaust and discovered its in good shape, i thought it might be coked up solid, but its fine. Flushed it through with the citric acid anyway and rinsed it out before liberally soaking it with WD40. It'll smoke like crazy for a bit but should be fine once the bike is running.

Also find some RTV in my box of stuff, so going to use that on the JAPton covers to try to reduce the oil escape!

The Ultrasonic cleaner just turned up, so once the cleaning solution arrives I'll get the carbs done and see if anything will fire up!
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Re: New Project(s)

Post by cheb »

Rockburner wrote: Sun Jun 18, 2023 2:20 pm Emptied the citric acid from the Puch tank today, seems to have loosened a lot of crap! Washed the tank out as best I can, and there's an inline filter on the way with the new tap to catch anything left.

I also whipped off the exhaust and discovered its in good shape, i thought it might be coked up solid, but its fine. Flushed it through with the citric acid anyway and rinsed it out before liberally soaking it with WD40. It'll smoke like crazy for a bit but should be fine once the bike is running.

Also find some RTV in my box of stuff, so going to use that on the JAPton covers to try to reduce the oil escape!

The Ultrasonic cleaner just turned up, so once the cleaning solution arrives I'll get the carbs done and see if anything will fire up!
I do like an optimist.
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Re: New Project(s)

Post by Rockburner »



Puch carb parts, after a clean.

JAP carb parts, before:


And after!
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Re: New Project(s)

Post by Rockburner »

cheb wrote: Sun Jun 18, 2023 3:58 pm
I do like an optimist.
Then you'll love this....

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Re: New Project(s)

Post by Horse »

mangocrazy wrote: Tue Mar 28, 2023 1:57 pm Zeus book
Still have mine. 1976 'Metric' edition :thumbup:
Even bland can be a type of character :wave:
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Re: New Project(s)

Post by Rockburner »

Since i had a clean carb, and a carb refurb kit from Germany, i put it all together, fitted the tank, with a new fuel filter, pulled the tank cap out of its ACF50 bath, put it all together and tried it.

Nada.

Eventually figured out the fuel wasn't flowing at all (which confused the hell out of me), until i stripped the float bowl again and realised that the float needle wasn't hitched into the float properly, but was jammed into the fuel feed and wasn't opening up. D'oh!

So fixed that, reassembled.



And the little fucker started second kick.
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Re: New Project(s)

Post by Rockburner »

Still got a fair bit too do on the Puch.

The twist grip is knackered, i did buy a new one, but it doesn't fit properly, neither on the bar in relation to the brake lever nor with the original cable, so I'm going to try to get one that's closer to OE. (The one i bought appears to be some sort of fast action item).

I also need to replace the from brake cable, somehow the sheath has fucked itself, so I'm simply going to replace the thing.

The carb is also pissing fuel, could be the flat bowl is simply leaking, but I'm wondering if i need to replace the float itself, i have a new one so that'll be easy. Then i can see if the leak is from anywhere else.
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Re: New Project(s)

Post by Rockburner »

Haven't got around to the JAPton carb yet.
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Re: New Project(s)

Post by cheb »

Rockburner wrote: Sat Jul 01, 2023 8:33 pm
cheb wrote: Sun Jun 18, 2023 3:58 pm
I do like an optimist.
Then you'll love this....

Excellent
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Re: New Project(s)

Post by Mr. Dazzle »

Horse wrote: Sat Jul 01, 2023 8:34 pm
mangocrazy wrote: Tue Mar 28, 2023 1:57 pm Zeus book
Still have mine. 1976 'Metric' edition :thumbup:
I don't know anyone who's actually bought one of those, yet everyone has one.
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Re: New Project(s)

Post by mangocrazy »

Mr. Dazzle wrote: Sun Jul 02, 2023 8:33 am
Horse wrote: Sat Jul 01, 2023 8:34 pm
mangocrazy wrote: Tue Mar 28, 2023 1:57 pm Zeus book
Still have mine. 1976 'Metric' edition :thumbup:
I don't know anyone who's actually bought one of those, yet everyone has one.
I bought three. I'm very good at losing things...
There is no cloud, just somebody else's computer.
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Re: New Project(s)

Post by Rockburner »

Tinkered with the Puch today, (no photos, sorry).

Replaced the front brake cable, easy.

Refitted the "airbox" and the various air filters.

Refilled the gearbox with ATF, bit awkward because the filler hole is about 8mm, and i didn't have any proper crush washers, so made do with rubber washers and o-rings. Not sure they're working very well so need to find a "grab bag" of crush washers. I'm buggered if I'm going to use fibre washers. Hate those things.

Its starting and running like a good 'un now. :D

Tried pumping up the tyres, but the tubes are knackered, so need to get a new pair, and fit them, which means buying some tyre levers. I've managed to get this far in life without needing any, not sure how!
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Re: New Project(s)

Post by Taipan »

eBay has pairs of 12"/300mm tyre levers for about £6 delivered. :thumbup:
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Re: New Project(s)

Post by Rockburner »

So, while the Puch is awaiting bits, I turned back to the JAPton and, remembering roughly where I was, I stuck some petrol in the tank and opened the taps.

No leaks was the first win!

I tickled it up but instead of fuel coming out of the tickler, it eventually started dribbling from the manifold, bit odd, but the fuel is flowing.

Kicked it a few times and eventually it fired up, bit rough, but some small adjustments fixed that.

Opening the throttle though and there's a lot of spitting and backfiring, flames from the open bell mouth. Not good. I'm now worried that the inlet valve isn't shutting correctly, with the throttle fully open you can look down the manifold and see the flame front!

Nevertheless I took some time to adjust the oil feed to the head which wasn't running, now running at (roughly) a drop every 5 seconds on tickover, just like the book says.

I'm going to try a smaller main jet in case it's just a case of over-fuelling, but if it's still backfiring I'm going to have to have another look at the valves.
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Re: New Project(s)

Post by Horse »

Rockburner wrote: Sat Jul 01, 2023 8:39 pm Since i had a clean carb, and a carb refurb kit from Germany, i put it all together, fitted the tank, with a new fuel filter, pulled the tank cap out of its ACF50 bath, put it all together and tried it.

Nada.

Eventually figured out the fuel wasn't flowing at all (which confused the hell out of me), until i stripped the float bowl again and realised that the float needle wasn't hitched into the float properly, but was jammed into the fuel feed and wasn't opening up. D'oh!

So fixed that, reassembled.
And the little fucker started second kick.
The technical expression for that process is 'preventative maintenance', ie you prevented it from working ;)
Even bland can be a type of character :wave:
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Re: New Project(s)

Post by Horse »

Mr. Dazzle wrote: Sun Jul 02, 2023 8:33 am
Horse wrote: Sat Jul 01, 2023 8:34 pm
mangocrazy wrote: Tue Mar 28, 2023 1:57 pm Zeus book
Still have mine. 1976 'Metric' edition :thumbup:
I don't know anyone who's actually bought one of those, yet everyone has one.
And I still have my British Thornton slide rule too :thumbup:
Even bland can be a type of character :wave:
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Re: New Project(s)

Post by Rockburner »

Horse wrote: Sat Jul 22, 2023 9:17 am
Rockburner wrote: Sat Jul 01, 2023 8:39 pm Since i had a clean carb, and a carb refurb kit from Germany, i put it all together, fitted the tank, with a new fuel filter, pulled the tank cap out of its ACF50 bath, put it all together and tried it.

Nada.

Eventually figured out the fuel wasn't flowing at all (which confused the hell out of me), until i stripped the float bowl again and realised that the float needle wasn't hitched into the float properly, but was jammed into the fuel feed and wasn't opening up. D'oh!

So fixed that, reassembled.
And the little fucker started second kick.
The technical expression for that process is 'preventative maintenance', ie you prevented it from working ;)
That would only apply if it had ever received any maintenance!
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Re: New Project(s)

Post by Skub »

Mr. Dazzle wrote: Sun Jul 02, 2023 8:33 am
Horse wrote: Sat Jul 01, 2023 8:34 pm
mangocrazy wrote: Tue Mar 28, 2023 1:57 pm Zeus book
Still have mine. 1976 'Metric' edition :thumbup:
I don't know anyone who's actually bought one of those, yet everyone has one.
It was a necessary part of the toolkit when I began serving my time. I still have mine (it's a mite dilapidated) and occasionally refer to it for drill sizes and tapping info.
"Be kind to past versions of yourself that didn't know what you know now."
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Re: New Project(s)

Post by Rockburner »

So - yesterday I had a bit of time so I scurried over to the workshop, giggling all the way, with my hands full of inner-tubes and tyre levers.....

First point of business was trying to figure out why the Puch was still pissing gearbox oil. :wtf:

It "seemed" to be coming from the "fill-level-hole", so I unscrewed the screw, cleaned the face of the hole, fitted a second new crush washer and doubled up with blue hylomar to seal the fucker properly. 5 minutes later there's oil dripping AGAIN.

GAH!

spent a bit more time looking at it (getting underneath it for a properly look is a pain), then realised there was a smear of oil all along the lower face of the casing... where the join runs. Grabbed a PZ3 screwdriver bit and went round the screws (yes, screws) that hold the casing on... and 3 of the 5 were fucking loose!! No wonder it was pissing oil! :roll: :roll:

So - with that issue sorted, I moved the JAPton around in the workshop to give me more room.

I'd been wondering how I'd get the wheels out of the Puch and realised I had the perfect piece of equipment which was otherwise superfluous to requirements.... (this is why I never throw anything away if it's still "working").


Image

It's a "sit-stand" desk unit that I was using during Covid when working off the dining room table. The spring in it isn't capable of lifting the Puch by itself, but the pneumatic brace is perfectly happy to hold the bike once it's up. Bit of a heave is all that's required. :D

Image

It even came with the brackets for the straps. :D (well - they're actually the brackets for the keyboard shelf, but they work fine in the new position).

So - lovely little work lift for a lightweight bike. :)

Very pleased with myself I dropped the front wheel out and proceeded to strip out the old inner tube.

F*ck me, I haven't done this for over 30 years (changed an inner tube), and with a 14" wheel the tyre was NOT happy to come off.
But eventually, with a lot of swearing and sweating it did eventually get over the rim.

Pulled out the old inner tube - it actually "looks" fine... but I think the valve itself was the leak (oddly). It's not a usual Shrader though, so the valve cores that came with the tyre lever kit wouldn't fit. So - I pulled out the new one and commenced to get it into place.

Bit more sweating and swearing and it's in.... get the pump out and get busy. :)


w.
t.
f.


hisssssssssssssssssssssss


The sodding NEW inner tube LEAKS. :angry-cussingblack: :angry-cussingblack: :angry-cussingblack: :angry-cussingblack:

At that point it was half past 6 and I had to be at the station to pick up the other half at 7, so I swore a lot more, left the wheel where it was sitting, left a very disappointed review for the inner tube on Amazon and stomped back to the house in a foul mood.

Anyone know a good source of RELIABLE inner tubes in unusual sizes? This one is a 14"/2.5 (the rear is a 12"/2.75-3.00)
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