The Italian Grenade Project #FINISHED#

RE: The Itilian Grenade Project

Sorry That was an Iphone keith but the canon was with me today.[]

So today I spent some time with the grenade.
I sanded down the exhaust (Which Is a Bitch to get off!) and sprayed it wit Very High Temperture paint.

Before



After



It looks as good as New![]

The end can has seen beter days and may be replaced by ebay if the funds can handle it.
SO much 2stoke oil leaked out of it that I reckon its been running rich for years.
[hr]
Naked


Next the airbox with complementry missing screws!


Alot of twostroke overspill in here and some unexplained paper???
New filter in the post.[8D]

Just a pic of the clocks and a nuetral light that wont turn off even when in gear?
ECLIPZE??? Any Ideas?


There was about two miles of throttle play and It all lead back to this being Broken![:*][:*][:*]


Airbox off


Carb out


The carb
[hr]
Brakes in a bad state, paint peeling.
Thanks to decent protective seals the pistons are fine and only have top rust where they meet the pad!


I will get another 10k out of them pads![lol]


Exhaust port/powervalve


Scratches on the Frame

Im guessing the side stand is faulty because of this mod to the sidestand wires![:&]



Everything I fix I see 10 more things that need attention!!!
Hope it goes well and lets hope the Big end is fine when I get to it!

Thats all for now, hope I get the parts soon. in the meantime that engine need some elbow grease[HB]


Car mirrors = Incident trophies! 1 and counting!
[hr]
Airbox Cleaned
[hr]
Powder coating the frame is not an option unfortunatley it is way over the budget.
Is there any way I can fill in the scratches? And polish it down to be flush with frame.

I managed to source a good throttle housing with cables in a local breakers today for 15e.
The cables in my bike were in better Nick so I left them in and now I have some spares!!!



A bit more naked!






Didnt get much time at her today so I'm hoping to go hell for leather at cleaning the engine to mo.
I think the subframe, rear peg brackets and h frame may get a cheap spray and lauquer.

www.pjme.co.uk is a great site for these things, thanks again crash dummy.

I need to get a set of paddock stands that suit.
One that lifts the Front by the head stock.

The budget is nearly gone so I'm probly gonna go 250e over at least.

Rhory I will prove all 125 two strokes can wheelie!!!
I must upload that vid for the laugh! The wheelie is funny but your laugh is infectious!

Car mirrors = Incident trophies! 1 and counting!
[hr]
Powder coating the frame is not an option unfortunatley it is way over the budget.
Is there any way I can fill in the scratches? And polish it down to be flush with frame.

I managed to source a good throttle housing with cables in a local breakers today for 15e.
The cables in my bike were in better Nick so I left them in and now I have some spares!!!



A bit more naked!






Didnt get much time at her today so I'm hoping to go hell for leather at cleaning the engine to mo.
I think the subframe, rear peg brackets and h frame may get a cheap spray and lauquer.

www.pjme.co.uk is a great site for these things, thanks again crash dummy.

I need to get a set of paddock stands that suit.
One that lifts the Front by the head stock.

The budget is nearly gone so I'm probly gonna go 250e over at least.

Rhory I will prove all 125 two strokes can wheelie!!!
I must upload that vid for the laugh! The wheelie is funny but your laugh is infectious!

Car mirrors = Incident trophies! 1 and counting!
[hr]
I got a few bits in the post, airfilter, smallend rebuild kit, fork seals and misc bits.
I have cleaned the carb but am still waiting for the haynes manual so I can set it up.
Here is a few pics of progress.
I have chosen the colour scheme but may leave that a secret until it's finished.

Thanks to crash dummy I have bought alot of bits big and small from www.pjme.co.uk
I'm replacing the back shock, the chain and sprockets, gear oil and I have blown the budget!
The new revised budget is 1000e including the price of the bike, full rebuild and new tyres.
I would like to say thanks to an Irish biker who is giving me a free can off an rs 250 which will fit the 125.

Pics







Car mirrors = Incident trophies! 1 and counting!
[hr]
Some small progress!
Thanks to Osiris for his painstaking work[)]

frame given the first of many light polish jobs with the polish amchone of justice!


see the differance between polished bit and non polished of the swing arm


sprayed rear hangers.


destickered plastics, not fun!




so that was about it.
May pull off the head to mo for a treat!
Have alot more to do!

Car mirrors = Incident trophies! 1 and counting!
[hr]
Today I got down and durty with my new itialian girlfriend!
I removed the rad and I have to say she is in great Nick!
back to high res pics Keith



just getting started


water ports.


T he power power blade came out, I know I thought it was a funny name too!POWER BLADE!!!


Head off, the piston is in fairly good Nick, the bike has 9,400 miles on her and it's hard to tell if she has been rebuilt before.


side angle


The cylinder is in pretty good shape too! I am happy enough to put it all back together wit a new piston, small bearing, gudgen pins and rings.

The big end has side to side movement (it's supposed to) but it is solid in up down movement so I am happy and releived.
I am waiting on a gasket set and manual still so there will be nothing done until weds.

Just a few Qs for those on the know, what should I clean the cylinder with, the reeds, the gasket sections and the POWER BLADE!???

Any other tips and tricks?

Car mirrors = Incident trophies! 1 and counting!
[hr]
Out with the old in with the new!

The old piston was not in bad nick at all but I got no history with this bike so I decided to go ahead and replace it seen as I had the parts.





Its a bit tricky getting the little bastard out and the new one in especially without dropping the engine but its doable.

New piston seated and All is going well so far.



Carb back in.


Carb and airbox back in.



I TRIED to fill the gearbox oil today but made a mess of it.[B)]
I dumped the old stuff without meassuring it.[:I]
Then tried to fill the new stuff but the measure glass is impossible to see through![:*]
The haynes said it takes 830ml but I think thats in a dry engine.
Does anyone know this off by heart?
Really dont want to make a mess of the project on something so simple.

Also, the Haynes has no setting for the jet??? so does anyone know how many turns out the pilot jet goes?
Just to get me started.

And the IDLE?

Please help!

Car mirrors = Incident trophies! 1 and counting!
[hr]
SHE LIVES

I have provisionally built the bike back up into "Running Mode" as i like to call it.
There is still a huge amount to get through but I had to build her to this state to check that the engine went proper good!
I will have to take alot off to replace the shock etc.

Here is a pic of the old spark plug vrs the new irridium.


This is what you have been waiting for, the video of her running.
Just want to say a big thanks to TOM for the Free exhaust!:thumbsup2:
It took some time to get the Idle right and the pilot screw set so she would rev up but she is running sweet.

Enjoy.


Car mirrors = Incident trophies! 1 and counting!
[hr]
From what i can make out my jet says x25 or x125 and it has four needle positions while sitting 3rd from the top???
Must be after market?

I came across a problem today, the throttle seems to be routed wrong.
When I turn Right the cable gets caught on the H frame holder on the frame causing it to rev up.
Is the throttle routed behint the right fork leg???


As I am still awaiting Parts I decided to go at the evil fairings!
I mentioned before about spray cans being used so I have had to fight fire with fire and use NITROMORSE!!!
I have painted over spray paint before(on a race bike) and it chemicaly reacts cracking the paint.

Fairings






Nitromorse




After



That is just with one rough sand down so I expect another 3 more gradually lighter sanding sessions shoul have them ready for primer.
The paint will be one of the last things I do and will only be revealed when the project is finished!!!



Car mirrors = Incident trophies! 1 and counting!
[hr]
Oh the beauty of deliveries!!!!

In this delivery we have a new rear shock,
chain and sprockets,
levers,
front and rear brake pads ebc double H,
renthal firm grips,
power valve cable,
fuel hose,
fuel filter,
stand bobbins,
fairing screws and bolts also the most important tool, a spring puller! I have no knuckles left!



The real work starts tommorow!


Car mirrors = Incident trophies! 1 and counting!
[hr]
With the sun out today I got cracking on a good few bits.
The old powervalve cable was strected a bit so in went a new on as was set as per the haynes manual.



New fuel pipe and filter as the old pipe was rock solid and an in line fuel filter was fitted.


The old levers were in a sorry state so they were replaced






The old shock was leaking like a siv so out went that and in went this shiney new one!




The chain and sprockets were the originals on it so in wnet a brand new regina.
[hr]
The teeth on the old rear sprocket were in a bad way.


Nice and shiney!!!


I built here back into running mode again and even took here for a spin down the driveway trying to keep her under 6,000 rpm.
On the test run she idled perfect and ran smooth.
The brakes weren't great but they havent been touched yet and the brake fluid is nearly black.
The disc seems good and hopefully not worped.
The neutral light stays on constantly so Ill have to get to the bottom of that little itialian surprise.
She felt good through the gears but poped from first into nuetral once, lets hope its not an underlying problem.
Clutch felt smooth and all bearings were spining.
Thank god she has started first time every time even with the short runs and an iridium spark plug in her.

Another vid for ya.


Car mirrors = Incident trophies! 1 and counting!
[hr]
So today started off well and then turned to shit!
I took the bike for a spin to warm her up and help the pistin bed in, then i dropped the gear oil and put in the new specified 600ml.
I put lovley new oil caps on the clutch adjuster and the gear oil refill.
Anal i know but when I have gone this far I may aswell do it all.



The old ones had seen too many screwdrivers.



The speedo drive got a good clean!
God they get manky! took 45mins to de-gunge!


So I started to rebuild the forks.......


All went well with the first one




was starting to thinks this is too easy!


Then I met the other fork.
I had thought the seal was gone on this one, there was slight seeping round the seal but it could have been just dirt?
The first one was perfect, real good rebound with 15w oil.
It looked like the forks were done recently, the oil in them was spotless!
But this one felt like a pogo stick!
The oil was perfect and there was the perfect amount in it.... I started to wonder.

So I rebuilt it but its still felt like a pogo stick, I realised the second fork had an internal dampening spacer MISSING.
It sits in the stanction like a coin and has a couple of holes in it to reduce flow.
Its missing, not there, gone, dissapeared and fuck me am I angry at the last fucker who took it apart!
The haynes even says not to take that bit of the fork apart!!!
So overbudget and pissed off as I am so close to finishing this and now I have to go buy a set of forks!
The spacer doesnt even exsist in the Microfiche for the forks!

ah well here is the bastard fork.


I didnt even take pictures of the part as I was to deflated.
Anyone got a spare fork???

Car mirrors = Incident trophies! 1 and counting!
[hr]
Well the panic is over!
I have it on good faith from John in the itilian centre that one fork is sprung and the other is for dampning.
I have done plenty of fork rebuilds but never seen a system like that.
So I got on with the build and freshened up the fork legs as the paint was comming off.



sprayed up.


All back together


I also rebuilt the rear caliper and put new ebc double H pads.
I rebuilt the front calliper too but the pads I got were the wrong ones sent to me.
So they have to be returned and new ones sent.

Next day is the fairings and maybe some fethling some small bits.

Car mirrors = Incident trophies! 1 and counting!
[hr]
The real fairing prep starts.


Bad repair in this!


This is all I got done today. slow work.:bag:



I hate paint prepairing and these are very bad condition fairings!



Car mirrors = Incident trophies! 1 and counting!
[hr]

Originally posted by psidey
[br]
Project bikes are always more work than you think, but if you
have the time, the patience and you love doing it, then it's
all good. Just remember, you take one small part and make it
look great, and it makes the part beside it look not so great.
It is a never ending circle of refreshening all things until
you end up re-doing the whole bike. "Yikes, I never anticipated doing that in the first place". Have fun icle, it will be a treat when it's done.

Click to expand...

Tell me about it!!!
Now that the rest of the rest of the bike looks so well I cant stop staring at the bits of rust on the foot brackets!
Im strong enough to ignore it(but for how long????)
Knowing every bit of your bike can have positive and negative points.

So it was a lovely 20celsius in sweet Kildare today so I did what the Irish do best, I hid in the shade and went mental with a sander.
I got the whole set done and tommorow i will prep by hand the nooks and crannies with 1200 grade sand paper.



If the new fork seals are not here to mo I may go buy some local for a big price.[]




Car mirrors = Incident trophies! 1 and counting!
[hr]
Well the fork saga continues!
I got two sets of seals from a seal specialist (Abbeyseals) today and a set I ordered from thi internet.
Took apart the forks and the reason they leaked like hell was the replacement set I rebuilt them with were the wrong diameter by .5 of a mill.
The two sets from the seal company were the wrong diameter too even though I had brought the original seals for them to meassure.
The ones from ebay were so far wrong that they were 5mm off in depth!!!
So the moral of the story is, ONLY BUY GENUINE SEALS! and it is something I always do but I failed to take my own advice this time.
Now I am paying or it!

All I did today after that was put new grips on and some crash bungs.

Old grips




New rental grips




Crash bungs.


Car mirrors = Incident trophies! 1 and counting!
[hr]

K916 said:

Good stuff !!!

Cant wait to see more pics as the project progresses

Click to expand...

Keith, I think you will like it
This thread has been coppied from the old forum so thats why some stuff may not make sense.
It wasnt finished so I had to transport it over.
Got new fork seals that look nearly as good as the originals so fingers crossed they fit tommorow!
Also pick up some stuff on Tuesday.

Thanks for all the support so far!

RE: The Italian Grenade Project

With the forks rebuilt we are back on TRACK!:headbang::headbang::headbang:

I added some very dodgily cut frame protection hard sticker. This adds 10 bhp to the bike!





I really did want to surprise people with all the fairing pictures but I got these for a bargain and I have to tell everyone!











I am over the moon with them.

Tommorow I hope to bleed the front and back brakes,
Replace water with coolant,
Fit the brand new never used exhaust I was given by the same lad and
Fit all the new panels.

I still have to find a tank cover in the right colour and condition and I have found a new but expensive yellow front mudgaurd.

I also have not lost hope in the evil fairings.
In time I will finish and paint them as spares or to sell on.

RE: The Italian Grenade Project

Tanks psidey!
She is finnaly coming together.

But first have a look at the colour of the old brake fluid compared to the new stuff!


There are still lots of niggly bits I want to get or her but for the most part she is fairly complete!









The tank does not match the paint perfectly so i will keep a look out on ebay, its black and the fairings are greyish.
The side plastic panels will be replaced as they are scraped.
I need a black V peice.
She will be getting a genuine new yellow mudgaurd on thursday.
A new front tyre is needed.
Road tax is a must as she has not been taxed in 8YEARS!
I also have to ring the insurance company! hope that goes cheap!

What yas think so far?