OzVMX Forum

Marque Remarks => Honda => Topic started by: alexbrown64 on August 19, 2017, 08:30:26 PM

Title: New XR75 K1 1974 Project
Post by: alexbrown64 on August 19, 2017, 08:30:26 PM
Well, my sister sends me a pic of this bike today and says her partner picked it up for me..
Checked serial numbers and starts with 11..... she's a 74 K1.

Luckily i have just purchased a full Jane zinc kit and heaps of other goodies to rebuild VMX bikes. She seems to be mostly all original, but the side number plates seem to be painted like a 75.
Lots of time to be spent on this old girl...

(https://ffd1mq-bn1305.files.1drv.com/y4mjgMqnfJENg_vZoZ7TZjy9nNOtExPB_nh1IiupYph9ywJu0jfk9YLquQ1MxjLr9bc7VmHyJL67pFyreFagfh6HaEFD8tHHmQFIsqPUHN-7yOyAkfhrwbBTITfpWfKrva-g9uotPdNUReRMiiL1ocoNQHqdtSALKbhFjNCIpn0IFBU9F4-M8LU2bMcDdcgjqrsvw832QrVr06eY2WiYS5wzA?width=660&height=371&cropmode=none)

Cheers
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 20, 2017, 01:38:15 AM
Does anyone have an original 74 with original side and tank decals.  Every K1 XR i look at has either yellow side cover decals and orange wing tank decals or visa versa or both the same in yellow or orange. The blury brochure pics i have show the darker orange yellow for all decals, but some guy put a pic up of his original XR and they all look yellow.  Which combination was it?

Cheers,

(https://is3d1g-bn1305.files.1drv.com/y4mKrJBWUbGJ8b5k7WCr3QynTH4kHyhBiCv-yMja_HJDoR673_87chLEJwlum-BTpQyh1rJmhcR93nr4qErHDfRWGPo8DoHDYRvq1UzsjQ6ey3AL-ZEASxGZgszqBzIND-jJG1Tc0qodvSKU__ckNI3aq7hh-Fr3G_SpvKFAyp2wF5ZZZ1Xtx3YcWIqLzbUSkWivDYgqYeStEadbhmwAJysyA?width=660&height=370&cropmode=none)

(https://js3d1g-bn1305.files.1drv.com/y4mHxWR14I2hVRuCRO46p5luYgrZLC9gejWxyFVmQ7pInOc_ZxljDfjG5E22srgjYy6A42jTpwrselraTzpkjdx5xsPbK5bCvF-hHhT-CdSKDSM0dtzjL42bbqGZLIjFmeRynGY--3dgjNsKLrnbVl7SuBs69dN857rPhfs7Ve_yReQXgni6cZwZklPZOWYX9G1uY8QNgARxa13OKxnvJ7LKA?width=660&height=437&cropmode=none)

(https://im3d1g-bn1305.files.1drv.com/y4mDGliHgwWB7gzbxfJ3lbn8uV9sT6oiK5ydAyPC-mTdW-ITjrKdHE9K4RcDCz_f8kd8QS1L3gs-TTs36gHrm6c1mPUCf7wC0UlpBFYSZHrLvL4EFHjrvNUjYrf6tB4uxD_uM7X_mou1mHIujTDKCzbdPkCUgi0F7s999TD3flGLmG-1KbjDwDLfHXmQ_TVl_m_zsthQti9cLzCaqhDypqn9A?width=600&height=315&cropmode=none)

(https://ffbavq-bn1305.files.1drv.com/y4munkKEmrIVOABQvGYlUU8L0QTo14L8BZe2NOEQdn9JdJIUUy8OGPPgynt8GBoYTWfyWgaBza8AJAjt1wKg4WDP4M4MzwAqet5KCpTBR69ECjxPy_LtWikRGuh7i1Rp5nBDp23eVYjyizrRpzVXAgqTFIk2_3YpoQCFJUYZFbkgNJXSzIc-PAUHuR_JydvDaO4RUJzBquzM9IOSKxQ94wMyA?width=284&height=276&cropmode=none)

(https://h83d1g-bn1305.files.1drv.com/y4mLc-xS9kkmWJGX-C2NdrMt4kpZsp0oTDM2pmZ9o5NRU7GDJbm1n0IwMVDimryiLxyTeiC7-1qN_fVlp0pwteySuTJhG75eEQwORudf16YBDc8XOim0KAQ7rAkK5nfwhagnQSZrwtGQ-5KZ2USeqNJVg1CayKPfGe1Pe-h_E_x6ih7I_UquaBd-0cAKOKMCcX-Ne-K0mHHYJGPVBKuxAjtiA?width=660&height=495&cropmode=none)

Title: Re: New XR75 K1 1974 Project
Post by: Richo52 on August 20, 2017, 03:40:30 PM
Nice score Alex,yes yellow is the colour for decals on the K1 ,my mate is restoring 3 or 4 early XR75s currently.
Regards Richo.
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 20, 2017, 04:28:04 PM
Hey Richo, yep, they are a great project bike.  I think i had my first crash on one of those at the old RKMCC track.
Yep, yellow is the color, but all the decal companies come out with two yellows.  A light yellow and a darker golden yellow.  Re-Mx has both colours in the same kit? Lighter number plate and darker tank.  I have a book i have had since i was a kid and it has a colour pic of the K1 and it looks like it has the darker richer yellow like the brochure i put on here... But then the pic of the original bike below seems to be more bright yellow.
Hmmmmmmm.....
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 20, 2017, 05:04:25 PM
Heres a good example of somebody that has got themselves confused by using some of the graphics kits that are out there for XR's

(https://jc3d1g-bn1305.files.1drv.com/y4mCxy4_nPMU9ATpr7LdS1JHUyivW1fSO-4CBnTWQQIwhePODO9U_vMheI9Ry4Mz-5e9IDgSR9Dr8t7WV2piCr1oiyKBVfWnBonxTrLDuC70I5mvaeQ6IelMF8YY3wbTkCCgSqHJmgJw65TwF1KlIJbCS23T-YFNb8T8GJbfADNZfD3uTV57MCldWiLmXf_WEzdnEyQoGKXUzSKiDOf14VtLQ?width=440&height=660&cropmode=none)

The richer yellow wing or lighter yellow plate decal?  I don't believe you can have both on the one bike.
As for paint, my research is pointing towards Kia Sage Green Metalic paint code EAB. Apparently the K0 and K1 had a greenish tinge in the grey.

Anyone tried the 2k urethane spray cans that are available.  I am looking at spraymax 2k.

Also, the pipe is OEM but hammered.  This is going to give the Pipe King a real workout.

Cheers,
Title: Re: New XR75 K1 1974 Project
Post by: Richo52 on August 20, 2017, 09:27:04 PM
Whatever yellow you decide will look good on your restos Alex.Im in the process of getting bits to complete a yz80d ,obtained everything for my 2nd RM80b but want to make that one an FMF or DG  replicabike depending what head comes up first.
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 20, 2017, 09:36:59 PM
Sounds like your super busy too.  The B's are a great bike to work on. My mint B runs like a Swiss watch, but the boys N runs like a turd.  I have a new carb, new ignition, everything.  Am pulling it back down a bit and adding a new stator side seal, clean out carb, check ignition, add the B stinger instead of the bigger DG one, and fit another cylinder i have with stock new piston and rings.
Hope to get it running right for a VMX meet later this year.
Be good to see a pic of your B's at some stage.
I remember the YZ80D.  It was pretty quick, but didn't sound half as good as the B. I think the C was better than the E, but i reckon the F and N of 79 were pretty much on par.
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 22, 2017, 04:37:19 AM
We got the little XR home and the boy loves it. He really wants to ride it, so the plan is to get it going for a few meets later on in the year.
It actually looks better in real life than in the pics.  The patella in the worn tank is amazing. I am going to paint the side panels and mudguards, but i am going to leave the tank with its rust, green and grey hues and knee marks... The tyres are brand new and i think someone had a go at "doing it up".

(https://jm3d1g-bn1305.files.1drv.com/y4mZks2U7Yj2PGfPVw3yCDXmnhDbyo3CtwRCwg0ZSgCw_lRmtFvLBIXLoXbbtr_jfde0GaQwA5NQMTmk4Umrq6KiJQXZ6QNGVIpncHYn1hAJZnmWZMQf2xOLTH7Diav2Y87-vQmjzFsPhLjI2IAXSLU-Wo0DdGAkqonRZLQqkzCtXoCvTy0d6RwTrdXOIPXq7uRDN5eV7esKQjhabYq1iHVag?width=660&height=371&cropmode=none)

There is a lot of work to do to the bike just to get it to a meet. Big list keeps growing.  The pipe is coming off and the Pipe King is going to have a look at it but its not an easy job. But thats for the OEM restore in a few years time...may even have to hit GMC up at some stage. There is a nos one on Ebay and guy wants over $1000 US.

In the meantime, i have ordered one of these bad boys complete with the DG decals etc.. This should liven it up and should sound great... i got it on special and he threw in a set of alloy engine mounting plates and it comes with all the mounts etc.

(https://i83d1g-bn1305.files.1drv.com/y4mKO9RGzD9rVkqgYqxvgMhdh868TFtdUBFOd1-nhjQKakNWTfCLUPvwMros5W20akv2TJqeDQbZ1LpE6DePTg7n73BoVumnf3rJlyoHJtof-h5WclcuwXpNv1WY8cPL5mqt5zQRROW13oDdsWKz2SmAqv2KpkqZF-M1mee6dCq6PA7IpA3woZnh1jlLhndO7NuHUledGZFL_rresuI--n39w?width=660&height=660&cropmode=none)

Cheers,



Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 22, 2017, 06:33:27 PM
The previous owner said he couldn't get it to run.
No wonder.... tank was full of flecks of rust, petcock was full of dirt and leaking, carb was worn out and full of crap, the coil looks like the dog got to it. The airfilter had turned to dust and was just getting sucked into the carb...

I cleaned everything up, got rid of all the dirt and rust, cleaned the plug, wiggled some wires, added some fuel and it started second kick for about 2 seconds.. then died.  Hardly a spark again, fuel dribbling everywhere, backfiring... Mechanically everything is good.  I checked the valve clearances, compression is really good, but the carb and electricals are just too worn out to get the job done, and the petcock is knackered.

We want a running bike, especially before we tear it down and rebuild it ready for a race meeting.  So it was off to re-mx.com and ordering some parts express post to get here asap.

We have ordered a new 20mm carby, new 6v coil, tune up kit with plug, points, condenser, full gasket set and petcock rebuild set.
The original carb and all original parts will be set aside for the complete restore later down the track, but for now we want to get her running right.  Hopefully get the new DG performance pipe on, get all the parts on and get her revving.

(https://gs3d1g-bn1305.files.1drv.com/y4mKzJuuPpfMoPDe0sQ9llRBRtn39F1P1OaYuW1ZVa7wfE0Zcs-x2u47w98Z40pSxhNIzqWP010iBf4rXh0LlKLuH_K3KPCHdKDpA18ItNs-FWb4KzkYqKPOB1mRFe3fODrmsMLhkYPi7jv-o9W2US4NG5pNasNyU3z5U7_phedHiBKTxEbm9qLUhGyrakwkDFg2wNJZIBtcRJX-sUYGPK94A?width=660&height=358&cropmode=none)

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 23, 2017, 11:01:45 AM
Massive list (160 parts) of genuine Honda parts coming from Partzilla.
About the only big hurdle at the moment is a broken footpeg mount.  These are actually an alloy block which forms part of the engine cases.  Its snapped where the bolt runs through.
Just wondering if anyone has used this process for case repairing aluminium.  Looks easy, cheap and strong...

https://youtu.be/2rH681CYDgw




Title: Re: New XR75 K1 1974 Project
Post by: Momus on August 24, 2017, 11:23:29 AM
Best and really the only sound way to repair the broken foot peg lug is to replace it with a sound case. Those brazing kits are useless for dirty work.
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 24, 2017, 02:49:52 PM
Momus, The Durafix HTS2000 rod seems like a great way to fix some repairs.  Just have a look at the first 1 minute of the video.  It also shows you how to do a bolt repair exactly the same as mine.  Pic below of the repair spot. The case has the engine number on it, and i want to keep it original, so it has to be the repair. One trick is to drill and tap a few small studs into the block to give the new material more bite.

https://www.youtube.com/watch?v=2rH681CYDgw (https://www.youtube.com/watch?v=2rH681CYDgw)

It also shows you how to do a bolt repair exactly the same as mine.  Worst comes to worst, i have had a quote of $150 to tig it all up.

Here is a table of the new rods strength.

Tensile: 45,900 PSI    Therm. Exp.: 15.2 x 10- 6in./in./Fo
Elongation: 10% in 2 inches    Elec. Cond: 26 (% of copper std.)
Impact: 43 Ft. lbs (charpy)    S.P. Grav.: 6.6
Shear: 31,000 PSI    Weight: 0.24 lbs/cu. in.
Melting Point: 380oC - 408oC    Rockwell:  48

(https://ic1cyg-bn1305.files.1drv.com/y4m87GOabewkZW6j17dgZug7YCZdp4NJplfwMy0t5Xo8PAfJ2RwORF0GYibxop9I7Te0Wzhz4pHu53PIGj6ZtpBK3PCiFkb-dXeWZGv0IzeDjP4hEgWZWJ-Cukj8OXBfij07f6axjbOvHdrdVHNldSbpdABjOmsTikmRSVnzjWQ1ohVZgNNYgyubBsXt-p2nmIgo20hbw0tAt1cVEuBzNrcWw?width=660&height=371&cropmode=none)

I pulled the seat apart and the original sponge was toast.. i have ordered a new one, and another seat cover from re-mx

(https://gc3d1g-bn1305.files.1drv.com/y4mbX5B8gIcCQa3HDMPIjrLwe6UfPnC0HBsTMAavDEF7a5PTpS2wu6WNjv3_g5Z0L63gBIdUXQ-gU8dBqOerIHjVha6ksD_vCwjvGrgJ_KS863Kdt1QuK5RQsWOmeNvfHLVKja54dpKTThjUKQ1gy4bK3dI9bPEjEyphIE2NvwU0PXcmBwgXFgvpcPeTJL9TUQzBmzxCErNNLgxaYywVd1xhg?width=660&height=370&cropmode=none)

Here is a pic of the power pipe i have purchased.. its on the way now :-) ...

(https://is1cyg-bn1305.files.1drv.com/y4m0O0J66CQztN-DUcmdxM2LFJAEB06hsxx8R_1ZyRh776CUttVIeQf5YV7h0hzd1-FavY2S-ObT_UbaDG8SSxuegY4mH8vwwhFnPPs2kmTpdkaqsR3IgDEqFKUlYwnHb3r2v79wqOFw7SO-eLnWwB9A1bb_DXWb_HLWeOmuA6Wi4ukJy6KdqgKBQeKQHSM_scAen5lqpjO9SmNj4fF_gs9Ew?width=500&height=375&cropmode=none)

Another problem i have encountered is the dreaded welded gear lever to the splines.  I ground it off and both the lever and shift shaft are toasted.. no splines at all!!  I found a replacement 4 speed shaft and a new shift lever.. these are on the way too.

I popped into my local Paint Place and discussed the situation.  Walked out with a can of Kia EAB Sage Green Pearl Metallic which is supposed to match perfectly with the K0 and K1.  Also got a rather expensive can of gloss black for the frame.  This system matches up with the two cans of 2k clear coat i got.  The cans have the widget to mix the two parts. 
The idea is to lay down the rubbergray paint, then lay down the 2 pack clear.  Allow to dry, rub and then apply the decals. Apply a few more coats of 2 pack over everything.  This should be really glossy, tough,  and protect the tank from fuel spills.

Well, i have to wait now until the new carb, coil, plug, condensor and points arrive so that i can try and get her running and check out the motor, clutch and gearbox.

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 27, 2017, 11:01:24 AM
The little XR is pretty original. Most of the decals are still on the bike in one form or another. I will heat them up and peel them off and keep them on contact paper to preserve them.  When the frame gets 2k coated, i will put repro decals on.

Here is the airfilter decal...

(https://i80meq-bn1305.files.1drv.com/y4mwaFYoAAvKb167Vu0GHmlWUCiEFPRsognVNtApj6UOBFOSBvYTgYPsEcFadBepzamO9Ex79H2J9y_kJteB3GnXhqUz3bDFGFCFv_y9t8gSVDS29YViP7UbiY2oHq7EnqP6wrfiFFm-Vlmgfi7Rvp4H5OKy2rlKWv7MRukV5pNQ7Nit_tes3Yr0s6VBDvxRUb5dGcQnjr9Tx47WOTKHqELvw?width=660&height=495&cropmode=none)

And here is the Shock decal.  Most people get this wrong and put the new decals on the outside of the shocks.. but if your ocd, they go on the inside as per original.

(https://gs0meq-bn1305.files.1drv.com/y4mI4InCsaxgUae4YAxXR3Yy6jNpJpE77NkhiH_lMk3KTCQ3neUDin3IbAVYBHNm6F34zPSYwf1Yf4qFGx4oicMSzgAq7LhMp1hH_yHHJhfuDzHVhQnagovUPiDnOWJOG7DMaUbG3jl1_YyE49l5IHMeNbUGyde9uKVXyz73s3wG1ww89Ke6UAQYyycBa0X4Am815UhJVNg94XtasPYx5rLNA?width=660&height=495&cropmode=none)

Here is a pic of the steering stem decal. Note that the bar clamps are rubber gray. 

(https://jc0meq-bn1305.files.1drv.com/y4mD9a7jETHBn-fxvwWVK_yFmO3s5W9ESGj-_EEiVVdTr5Q0NZAkaMU9EB9_8828hlREo1ZIiUpbYWkRXvSxpTU_WO1ra9NMA1uOjXFJ-Ymisyy6j5yKH-Iua3UbJXo7fGjLHycWHQEUbvkrYSqX1yjCl6i0HgJt3trF5ZZgkIUcXLy9Ynv1zAuWya3ZtHlZ7wZgzKO7CsaavkE7IMIruJzyg?width=660&height=495&cropmode=none)

The tank had 4 decals.  Two orange wings and two warning decals.  You can still see the outline of where the warning decals sat on the tank.  I will be removing the dents, prepping, base coat and 2k clear the tank. Then put all the decals on in their exact location and then 2k clear over the top..

(https://gc0meq-bn1305.files.1drv.com/y4meWvEzWN_LpdVYw9RrisJV6WuZaGfDOLlddmIGle6cdMPDte-3RFwOSLuHltFVg8pIDFBnXxSEZM-1r1DVqwNc_i0BE-tM0o9ILJ8aqa-m7qQHeFnxKw0vkzcw0jAU5FGVoAdj3GKFQk8KBAlCKhpzSw83wWQantk88_Xzw5UM0WQ-ATIx1ocSJ8zdJtd-4uUWXVxDMEqPX4ibXBXIeXwIg?width=660&height=495&cropmode=none)

The swingarm had an exhaust warning decal. I will be getting one of these and putting it on over the gloss black and 2k clear coat.

(https://jm0meq-bn1305.files.1drv.com/y4m7kvTFmjlrazourH2D42NhJXpm0Q7M9ATb9olg9mVCC0sPSHWYKNdhxOpT02bR7Krd6UBJb9vtBw7Ve9rd5ZcktyyiW6nMJtIvKC5gaG8wYlkegWX6cRfy4R5fbvDraQhaw-5W4vcB2ow9A9TJl0ud9PNw8s8E8aiUkkG7uVHmBFviAqUEhEGcAMbb5iSARi1DvHAlxapK6lJ3hdjmErlqA?width=660&height=495&cropmode=none)

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on September 05, 2017, 12:11:01 PM
Parts arrived from Re-Mx and i immediately set about putting them all on.  It all went relatively smoothly and i managed to get a really strong spark with the new coil, condenser and points.  The new carb needed the choke lever bending away from the frame and then it fit well. Power pipe went straight on, but will need longer manifold studs.
I had to jam a Chinese shifter on the worn out shaft and really tighten it up so that i could test the box out.

Fired up beautifully and settled into an idle almost immediately.  Power pipe sounds great.  I snicked it into gear and rode off up the street.  Clutch good, gearbox perfect, engine smooth.. power pipe sounds fantastic.  Got her home and made a 40 sec YouTube video of her running.

She is now ready to be torn down and sorted out properly so that it can be entered in a few events. Even have a Vintage style jersey for the boy on the way..

https://www.youtube.com/watch?v=trVBRjKWtnU

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: Big Scotty on September 05, 2017, 06:02:11 PM
Gday Alex
I am enjoying your thread on the little XR,got me inspired to drag my kids old xr80 out of the back of the shed and do a bit of a tidy up ready for the next generation.i also sourced some parts from re mx after reading that's were you got yours,I have to say there service so far has been excellent,answered all my emails quickly,would recommend them to any body restoring a mini,look foreword to more updates
Cheers scotty
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on September 05, 2017, 09:03:40 PM
Thanks Big Scotty.  I forgot how much fun they are. Went up my road today with a big smile on my face. I am just putting another big order together with re-mx which should be the final order to get a decent rebuild.  Hope your XR80 is up and running well.  re-mx sells a bunch of parts for pretty good prices and really helps with getting the old girls up and running.

I have this retro jersey in a small size coming for the lad to match the bike..

(https://gs3wjw-bn1305.files.1drv.com/y4mObZa0geRYh-S1LDE1fU1CWl9XzICOULmquHZkr3R5zZ_yJqWE9uCvjQrPN8QeAFk52KWvABFbkBYA4-kPH9cXrqy2nslQE1fR_7gtX_e2oZCihRPKWPVUHjE4rxcPJN_MtRSvP3mfiMLdDkVPJG3f2pQzQ9bfzKtLqSZuLT620e4NO4ZOuv2n93QYigw7GE62mdp42nTaRBAEC8KbyvL1w?width=577&height=660&cropmode=none)

Cheers

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on October 02, 2017, 12:00:49 AM
Got stuck into the little XR.
As usual, the more you look, the more you find. The major problems are:

1.) shift shaft, which is stripped and had the shift lever welded on. 
2.) The footpeg bar mount. This 4 bolt mount attaches to the engine.  It looks like a pretzel and has numerous cocky shit welds and patches all over it.
3.) Pipe. Completely smashed and has numerous cracks.
4.) Rear brake lever. This was bent beyond recognition.
5.) Broken alloy footpeg mount on the engine case.

The rest of the stuff is just rust, wear, abuse and age. 
I pulled the bike apart and bagged everything up.  As this rebuild is just a tidy up to have her ready for a bit of fun, i am not going to far.
I straightened up the brake arm and got it ready for the powdercoaters. Had to make sure it cleared the pipe and was functional. 
I cleaned up, ground and rewelded the footpeg bar mount. Also filed the pegs.  These are all going to the powder coaters.
The pipe has been replaced with a  power pipe.
I have removed the clutch cover ready for polishing, and this is where i will go through to replace the shift shaft.
The alloy footpeg mount which is part of the cases will be repaired with the rods i purchased.

I used an abrasive flapper wheel and then a cloth wheel with white polishing bar on some of the alloy covers. I am having great results and will post pics soon of the before and after results.

Pic below of munted brake lever...

(https://ic07gw-bn1305.files.1drv.com/y4m7BEXK7T3bsf5mI-KLlldloqsHYADEOwZ8nvyaxPLYp3dF4r32MspxGPs2sdLgltYZ6PiGzmzIEuH7W1mCk-Ie19c8_yFHJdpsoHOm7aFH3EJtT4-QnzVYoxaBKmaNf15REgrQzpU2TvAPTfaOu2y6TxqJeLFgVnbWIC3C2oZ0qRJd3czJ8PhYTyEc0BzO773S6BetoyG2UO27iO89gI9Mg?width=660&height=660&cropmode=none)

Brake lever repaired and ready for powdercoaters..

(https://h807gw-bn1305.files.1drv.com/y4mENuXb_nIXVjZaLDZUlGs7PbMpcmmvqtR4H3A-XXs_3MZLwkwg7-AQTnJxqDxduoqe8NxBmZfooiUdimRanC_BUOUOe8nLocS7rbOKmpO0FfMDNu-tC4bw8A6Yng_GKIlAjg6qEILF0r9-fyK0buq0PmJhoozBcZhDuUVcQOaXwmpl0SpOdSFjvMpYdbfOqXsd24J73MzhEJC1y-xusYiQQ?width=660&height=660&cropmode=none)

The rest of the bike is bent, corroded, worn, missing, forked etc... but great fun to rebuild.  And she does run!!

(https://im07gw-bn1305.files.1drv.com/y4mKpVj3uEqnr7kRAw0WJVLttmg38NWS2-sDz773CP_sxy55pXkn-wUcyQYDGIVq6bAsFkp2w62JnlDDFagraQUV5HZBoEmaPQRLtB7xS9pOpZVetrQd7ufDLXzvEXMeoFAQu-vP9zElGK8nfETCogEVmU2kwpxtWpDPTOPZckVfpxigCJWxlYfjaBuYy64odcOh4lUc_q6O1mlAiWleDx11w?width=660&height=660&cropmode=none)

Cheers

Title: Re: New XR75 K1 1974 Project
Post by: Krikey on October 02, 2017, 08:47:20 PM
I'ma bit inspired Alex. I've got a couple of 74 K1s in the shed in boxes.  I think I'll have to start rebuilding at least one of them soon
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on October 02, 2017, 10:47:27 PM
Lucky you Krikey.  I think the K1 was the best looking model with its yellow graphics over the metallic grey.
Hope your two are in better nick than mine. Must admit, they are really rewarding to work on.

I had a go at removing all the old paint from the frame, swingarm, plates etc.. bought this biodegradable paint stripper from Bunnings.  Might as well of rubbed banana on it.  It was useless.  I could of rubbed it in my eyes and i would of been ok.  Had to go back and get the real stuff.  This had the paint bubbling off and i used the pressure washer to blast it back to bare metal.

Not sure which way to go with the black paint.  I bought 2k black and clear coat, but i am leaning towards taking everything to the powder coaters as i want to get the pegs, peg mounts, bash plate etc.. done in powder coat and i also have my YZ125G frame to take up and get done.

 

Title: Re: New XR75 K1 1974 Project
Post by: Big Scotty on October 03, 2017, 03:09:45 PM
Gday
Got my parts from re mx,new seat foam and cover,new fork legs,been busy out in the shed and got it all back together,double checked everything then time for a test ride,do you think the basted will start,I have had it running on the stand,first kick every time,now it's back on its wheels it won't go,time to walk away.bloody hondas????????????
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on October 03, 2017, 04:36:57 PM
Great to hear Big Scotty that you got the XR fixed and ready to rock. Strange that it wont start.  Best to walk away and have a think about it.  Cant be much.  Been sitting a long time and may have pulled a bit of crud through from tank or airbox and stuck in the minute jets.
Once i put my new carb and coil on, my little XR  burst into life easy..

Post up some pics once you get her running..

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: Big Scotty on October 03, 2017, 04:57:28 PM
Got it going,lots of fuel leaking out of the carb and I think some is running into the engine as well,did you buy your new carb from re mx and how was the jetting,I think either a rebuild or new carb
Title: Re: New XR75 K1 1974 Project
Post by: Mick D on October 03, 2017, 09:51:21 PM
Got it going,lots of fuel leaking out of the carb and I think some is running into the engine as well,did you buy your new carb from re mx and how was the jetting,I think either a rebuild or new carb

Nice,

I think the Rubber tip on the float needles go dry and hard in the  absence of fuel and use.

Anyhow that is what I found with the XR500 when prepping for the Bulahdelah Vinduro.
I always undo the drain screws on the carbys when stood up.
It had been sitting unused for a couple of years.

Kept tapping the bowl with the plastic butt of a screw-driver. Would sort of nearly stop leaking,,,
But eventually did after a few days soaking with fuel again,,,,

Moral of my story for me is = start them and use them more often.
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on October 03, 2017, 10:04:54 PM
Got the carby from Re-mx, as everything they sell seems to fit and work well. It fitted straight up, but i did have to bend the choke lever away from the frame. 

Didnt touch the jetting.  It started straight up, idled perfectly and i took it for a blast around the park and it ran perfectly, even with the new power pipe.  No burps or backfiring. And this bike has been abused, so im sure yours will be fine.
 
I did make sure the ignition system was good, by replacing the coil, condenser and putting new points in and setting the gap.
I also adjusted the valves.
I cleaned the tank out.

So far i have bought a set of rear shocks, carb, rear mudguard, points, coil, condenser and a few other items from Re-mx.
I have also bought a huge heap of OEM nuts, bolts, grommets etc from Partzilla.
I got some of my decals from Fastguystuff and the others from re-mx and partzilla.

The K1 is now ready for the powdercoaters.  I am sending the frame, airbox, pegs, peg mount, bash plate, seat base and a few other nick nacks all to be done in gloss black. I have stripped the paint and buffed all the parts. The swingarm i am doing myself in 2k gloss black. This is so i dont have to get the rubber bushes removed and replaced.  I did it once on a similar swingarm and it took the shop about an hour and a 10 tonne press and new bushes.

As usual, there is more work involved when you get pulling them apart.  I now want to strip the wheels, buff the hubs and replace the spokes.  This is still only a basic rebuild, but i want it to run and look reasonably smart.

I have also been playing around with various techniques to buff the engine.  Its not perfect and not oem, but it looks respectable and gives the bike a bling factor. So, i will have the rubber gray paint, oem style decals, white front oem plate etc.. but will have polished engine covers and hubs.

Bits i gave a quick buff and polish today... one of the brake plates hasnt been done yet.  If you have a look at previous pics, you will see the sad state of the covers..

(https://vkhqba-bn1305.files.1drv.com/y4mc2jJx4lr9tyWka5mvXcm7NCTq54IGPcdN6XsN94EqtnB1wRCS2jc53Le9eJ_wEX4uDqGmW_C7D8cDgaTyhUDZ2Ev9K5UdRkux5Vwjs_F-7q1c4MiGZk32voY8Cg2n9RvlfoJ4GZ9EyulE7SLGopmODaZFTaZJQI5LTudjo-retPu1oUd0pSxbXhSGO3pcshycl-XZ5dAc2Z6Qi-Mmsk65g?width=660&height=371&cropmode=none)

Some of the stuff thats going off to the powdercoaters.. mixed in with some of my YZ125G stuff...

(https://tuhqba-bn1305.files.1drv.com/y4mtadgFhm6s5Q-dCn2AwzBeR6KFOUrpRVzo28vrRNGjNWBPQoUnd2k_0awVQCdNCR6_rVP7yBYmHmtnVed0m1pnbNI-YXIgU_zGMzzmof8xkwQWgHrySQJFYEzmCnT5p9fYlkDKBhXZ_XpCaoCOuHrw42xOT9ibrBsXPYQ_FICrMLvmIiJamjvI_UJ3bjHc1AkAdkmD2v1q3jQ90fsJneO5A?width=660&height=371&cropmode=none)



Title: Re: New XR75 K1 1974 Project
Post by: Big Scotty on October 04, 2017, 08:17:13 PM
Got a rebuild kit for the carb coming,will give that a go and see what happens,fingers crossed
Title: Re: New XR75 K1 1974 Project
Post by: 80-85 husky on October 04, 2017, 09:07:34 PM
turn the fuel off and start kicking, if it fires, its leaking into the motor when the tap is on.

full throttle, kick like crazy or push it.
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on October 05, 2017, 03:00:36 PM
Hope the carb rebuild kit works out. When i eventually rebuild the bike for show, i will put the stock carb back on.  I just want it to run hassle free, and the Re-Mx carb works well, looks the same and was cheap enough.

I got up early and pulled the forks apart.  I dont think they have ever been apart in 43 years.  There was just a brown sludge in there and everything was dirty, worn, rusty and in need of an overhaul.  I put degreaser and paint stripper on the legs and washed everything down.
They are easy enough to strip. Pull the dust cap to reveal a circlip. Pull the circlip and then pull the top tube from the bottom. Then just remove the spring and seal etc.
I gave everything another degrease and clean up.

Next was a nice polish and buff of the bottom legs. Cleaned the chrome on the sliders and began reassembly.
I had new Honda OEM seals to go back in, and a few new drain bolts and washers.

I reassembled everything using 110cc of 15W fork oil in each leg.  The forks now look and work pretty good.  Wish people would take  better care of their stuff.  This old girl certainly needed a birthday.  Luckily Honda makes things pretty good quality so the original parts last.

(https://u0fpka-bn1305.files.1drv.com/y4mAQLZky_SC4MYo7pJpCTL3UKbDLABuf5u1ud4GLbo-42Eq6X9tE0898n_T-5fJ_QeyVjd-wtC_Z4bwhiL9i_MLO02GJlbzk3z9mg-R-24uTj_itTz82rRqmXXG5325Pt3Wjm0ekUJU9xeGcrUGUnHnxfjd4MVQ2Cs1LjJwyuMQCLiBgh7-7hLS-D-6lXHyS8liEgvpRe-59tJ6Q5AzRgIHg?width=493&height=660&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: 80-85 husky on October 05, 2017, 04:44:41 PM
lucky the tubes wernt pitted badly. looking nice and shiny... i got passed in my first race on my Gemini Boss 80 by a k1, thought it was the bike to have...i didnt have the dough >:(
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on October 05, 2017, 07:38:10 PM
Hey Husky, the tubes aren't pitted, but there is a small patch on each leg under the dust cover that has had the chrome worn away smooth.  Hope this doesn't affect the seals too much. Yep, the XR sounds like it was a bargain in todays dollars, but i bet back then they were quite expensive.
Haven't seen the Gemini Boss, but i have a pick of the Gemini Fuji from the same era...

(https://wefpka-bn1305.files.1drv.com/y4m64ULwzJAWtnjowq3Jtt0msj4rY9ig-B9zFU5EY8O8cHYLXSiOfEXtqC8FrLo360MJutGd2qEVfqFfXQNeDBq8Z-GCOnlVfw5PERawecfzw8Wq0rWPCwMQemc7MGG8hoWCv7ZYC2GNYsfiwvOFPm6qtwlXWk3I-GYaYoq6wPC9ql7r33kIGJiBdSbqYBUXnUHzvpKAEeGxErznK-erQShLw?width=615&height=660&cropmode=none)

I am going to repaint the tank. Have the 2k paint and decals.  Have to remove a few minor dings and prep everything. I have measured up the location of the decals.  Funny thing is the left and right seem to be about 5mm different from each other.  Maybe the dude in the line that put the stickers on only had to eye them in....

(https://ukfpka-bn1305.files.1drv.com/y4mD3Z-0KY111JY5b6HM-uidDojB8Isvb5j9romxQvR6_zY7iysTNCa141C42-R8xTrd_AdREKC931sBWbubvzQqCy8qo3o4N1NNFR5-JpV-5-OZeyNySWv9zW0VfQs9rVqO_2CDWAk0rfYnELiURr9y9QfeZtOhynm8rx89OkgVBdJ9vYALpakvcg2BTDF9qyV-1CE-qbRyS0v-W_guKpyUQ?width=660&height=371&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: Big Scotty on October 05, 2017, 08:02:59 PM
Gray alex
My forks were worn in the same spot but really badly,one has a slight bend as well,I bought brand new ones from re mx cheaper than having my old ones rechromed,they look well made and fitted perfect,time will tell if the chrome is any good
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on October 05, 2017, 08:20:20 PM
Big Scotty, i just went over to Re-Mx and saw the tubes.  Great option for the future. $229 for brand new tubes, plus a full kit of seals, caps, washers and bolts etc included.
They also do a full chain and sprocket kit for $50.  You could spend a fortune there. 
In fact i have.  I just remembered i bought the seat foam and seat cover, as well as all my other bits. I bought a beat up old Haynes manual for the 73-76 XR for $20 and its actually not to bad. Its in the same condition as the bike, so they kind of go well together, but there is heaps of good info on rebuilding everything.
Title: Re: New XR75 K1 1974 Project
Post by: Big Scotty on October 11, 2017, 07:28:59 PM
Well my little girl lives,pulled the carby apart and put a kit in it,also found one float had a pin hole in it,found completely by accident,put a new genuine float in,started first kick,idled,yeh.20 minutes tearing around the yard grinning ear to ear,never went that we'll ever.next project get the 125 Suzuki quad going????
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on October 11, 2017, 08:51:12 PM
Very well done.  The little XR's are great fun eh!! Nice that its running like a ripper again.  Just took a simple carb kit and new float...(lucky you spotted the hole).

Post up a pick of the old girl if you can.

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on November 17, 2017, 04:07:48 PM
Got all my parts together and they have gone to the powder coaters together with my YZ125G frame.  All to be done with a zinc prime and gloss black powdercoat. (pic below is various G and XR components)

(https://tufpmg-bn1305.files.1drv.com/y4m35VxNugBd9mg0dSbaMGgL10YhRqiukoAI1Ikon-nh3wQHXwlGwTTDB6_cUqUFCYo8wrolguUp9uHs92lNF_SPaOFHbxV6c_RMR9eblWRBnOXHXRROIkmBadc_ltoqIZKdk-c89gyrwiuL1W7baddTgzhBxjdbAP_mFNzwnJZmJ2Q69Y_ObfpCIF80ci6wUkaLk7o8qiME56ZDkNUBoeAuw?width=660&height=371&cropmode=none)

Working on the engine this afternoon.  Have to make a special tool to get the oil pump/cleaner thingy off, so i can get the clutch off...

Have all the parts now to rebuild the wheels, so hope to get them together over the weekend...

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on November 17, 2017, 07:06:04 PM
Had a bit of time this arvo, so i hooked into removing the gear shaft. The gear shift had been welded on and the splines were knackered, as well as the oil seal blown.
First off was to remove the oil pickup filter thingy. You need Honda special tool #somethingorrather.. but to get around it, i just ground 4 notches in an old socket.  I also needed Honda special tool #costsalotamoney.  This is a an 2c piece that i jammed inbetween the gears to stop the rotation of the engine.  Its copper, so doesnt damage anything (except the 2c piece).
This all worked a treat and off came the oil thingy, the clutch, a few other doohickies and then the gear shaft just pulls straight up and out.

Thats as far as i got, as i am using some of my special ally welding wire to fix a broken footpeg mount using a propane torch.
We will see how this all works out when i try and fix it tomorrow morning with a hangover...

Pic below showing numerous Honda special tools and techniques....
(https://tefpmg-bn1305.files.1drv.com/y4mAuHMdouVsAnaekjMI0N9oumemF_KMBGocMGvuCbHPLfrP07o2rtgiCo5fG5bHXfXnmtgb4Ti8DR9faOU50aPXl9CH0eQyHbJ4pLqL-1C5JzbFJpdtzMR3QPwuu4zCsT_ZHCgOGvbhWjOZ6pKxJDj7JpQuoqAE_a1GoAM94N4t1gRbXEFQNo2Xr8p7ikSvZeckPATzI7AQiraaaP_kY_C8w?width=660&height=371&cropmode=none)

Cheers

Title: Re: New XR75 K1 1974 Project
Post by: TT5 Matt on November 17, 2017, 07:20:56 PM
U can buy a double ended chinca copy of the Honda special tool for 12 or 13 bucks on delay posted to your door
Title: Re: New XR75 K1 1974 Project
Post by: Mick D on November 17, 2017, 08:35:19 PM
U can buy a double ended chinca copy of the Honda special tool for 12 or 13 bucks on delay posted to your door

Bit late now Matt,,, but good tip for punters planning a job soon to come  :D

That thing you are calling a "oil pick up thingy"  ;D ;D ;D ,,, sorry can't help it Alex  ;D  , it is a
"centrifuge"  and all that grey paste is the worn alloy,,, like most likely your head camshaft journals
that are non-ferrous and won't collect on a magnetic drain plug.

Seriously great innovation to collect "heavier" (waste) from the about to be recycled "lighter" SG 8.5 to 9.5 lube blood.   
Title: Re: New XR75 K1 1974 Project
Post by: Mick D on November 17, 2017, 08:38:58 PM
Hey and great to see something interesting on OZ vmx again mate...


Ps; I hope your grandchildren don't look back in years to come and see what you did with their
Rare and collectable soft copper gear lock  ;D 
Title: Re: New XR75 K1 1974 Project
Post by: TT5 Matt on November 18, 2017, 02:31:42 AM
The tool would be for when it's put back together,from the pics it looks like the home made socket tool has done a lot of damage to the nut which I've seen a lot of when farmers used to do their own repairs to there bikes and use lots of silicon on the home made cornflake box clutch cover gasket resulting in blocked oil gallery ‚ seized cam and stuffed head
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on November 18, 2017, 09:44:11 PM
Hey Mick, yep the centrifuge does work, as there is a lot of old crap built up around the edges.. but the later XR75's didnt have one. 
I will keep an ear out for the Chinese version of the special tool Matt.  The nut is all good and i can modify my special tool to fit a little better.  I would of got a proper tool, but didnt realize i needed one until i was almost ready to go.

Took two steps backwards today.  After some mucking around, i have to take the motor up to Pipe King and get him to repair the ally lugs that mount the footpegs.  It needs a decent repair job.  They are all stripped, broken and munted.  Hopefully Pipe King can do as good a job on the mounts as he does on his pipes.

Next one was the wheels.  The original spokes were cactus and i had to cut them off.  I got a set from Thailand that i thought would go nicely on the build. 
Unfortunately, either they dont know that there are inner and outer spokes, or they sent me all inners.  I tried to get a bit of extra bend on them, but the bend area also needs to be longer to get around the thickness of the hub.
I have dropped Vintage Avenue and email with the pic below. Pain in the arse. 
It can only go 3 ways... He sends me the correct bend spokes..... he gives me my hard earned dosh back...i get a new set of OEM spokes from Partzilla at $2 per spoke/nipple.

(https://vuhjvq-bn1305.files.1drv.com/y4myzjZaNyIxQ79NeEL0SEadZ9dDnarGPp2u7S11DXaj6V_tR1H3CcglWtg_6a41LFQf76OhRxDsGz_5_zYyGieclR3tp-Npr2_rMR_6QwYCZz72SqU04SEklX8HT7mual0Q-k_4Ow5fjJYZZ9LM0dOp6jxxpB1sKIAUeFe5F_SvuIS95Qj3kH1p3YXJNZRfWzxXJdepC2z23SPYIm5aevjFQ?width=660&height=371&cropmode=none)


Cheers,

 
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on November 19, 2017, 02:13:55 PM
Got up before the kids this morning and did a little prep on the body work.
The plastic mudguards got a rub back and then some plastic primer adhesive followed by some primer filler.
The tank and side covers got some dents removed, followed by a rub back and some etch primer followed by primer filler.

Now to find all the small imperfections and fix them up, followed by a good rub back and then some more undercoat, base coat, clear, decals and clear again... (2k clear to  make it fuel proof)

(https://vehjvq-bn1305.files.1drv.com/y4mSzdq_1GwWS8yJnrP3uge3XA_MbJzlK3ZRVEUSy0kmlrmdbMr_LZCMpVuSI3kKs_-Y4ZCIARZ5rAk_z1gQ8K4Fkdo83d3vauWnPNKMjVR0cqPgO6afpkNQ8fxHOeC16ed729Rxq6YkT-YrmyLATmFVVqmX6foUWO0Wf16Wp58gg5s58oOzCt2URMiHuid52it7XJKmQg7Qi_YV5W94rGfIA?width=660&height=371&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on November 20, 2017, 11:07:36 PM
The rubber gray paint is supposed to match perfectly with Kia Sage Green.  Either my paint place mixed it up wrong, or something isnt right.  I painted all the panels with my Sage Green and they came out way to dark. Its a nice metallic grey, with a greenish tinge, but quite a few shades too dark.
I have also read on here that Hyundai Smoky Gray is a perfect match using a spectron analyzer. I will take some pics, panels and info down to the local paint place tomorrow and get it sorted.  Besides that, the panels look pretty good considering their age. Its only the base coat, so should be able to shoot straight over it when i get the paint correct.

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on November 21, 2017, 06:34:25 PM
The Paint Place mixed a test pot of Kia Sage Green again and it was way to dark.  Not sure whats going on there.. but anyway, i had taken in my old rear mudguard which still had a really good spot on it to run under their spectro thingy...
Came back as Mazda S6 Advan Silver Metallic. It was a great match for my OEM rear guard. They just added a touch more green and i was good to go.
Put down the base coat, and then a few layers of 2k clear over.  When its hardened up, i will apply the decals and then i will be ready to put some more clear over the tank and number plates..

(https://tehjvq-bn1305.files.1drv.com/y4mF9TOk3i6yqxo7PXnmbRO4EMfyYiTlo8MEyEbZidzzGIXJZb5GkfF_R9xk6rycj1JSthIdHt5aA38wW4k5MOnHV-EIOkuaGcOzt06pNjqv3AWgm6gC0kbrZ-I0WPWGIq3_H1k4YZpNLZDFYn3TTlDb2yw8p4BoXG7kJrMoZxQqtkx-i-KCEIIRMV8AMEeHSFhccTiPjsJANgO9VZnRkgAXQ?width=660&height=371&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: Big Scotty on November 21, 2017, 07:49:01 PM
Bday Alex
It's time you found another bike for your young bloke to ride,your not going to let him on this one????Looks good mate
Cheers scotty
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on November 22, 2017, 12:06:51 AM
Hey Scotty, this isnt the serious rebuild.. this is just the tidy up for him to go out riding. It is coming up nice though, but there are a lot of aftermarket parts mixed with a ton of OEM goodies.
Let him ride it for a few years, then i will strip it down again for a full original build.  I am keeping the original rims to be rechromed one day and all the little mistakes now will be fixed for the garage queen build.  Can't wait to get it going and get the boy ringing its neck with the power pipe singing......
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on November 24, 2017, 02:03:31 PM
So... been battling the mighty XR again.  Had a few wins and a few losses.

New spokes with correct bend are apparently coming next month.

The motor is at Pipe Kings (Richards) place.  He is rebuilding a peg mount, building up the threads on all 4 peg mounts, making a template to align the holes and retapping them all. Should be a proper repair and strong when he is done with it.

I applied the vinyl decals to the side covers... and the 2k clear ate into the graphics and created wrinkles... as well as i didn't apply them correctly and i got heaps of air bubbles in there.. tried pulling the graphics off, ruined the decals and paint..... then i decided to read the instructions... do not apply for 1 week after painting.... apply wet using squeegee...

Back to square 1.  I ordered 2 more sets of side cover decals.  I repainted the side cover.  I re-read the instructions and now i will wait a few weeks to do the tank the sidecovers.  I did however sand back the front and rear guards, and apply a metal decal to the rear guard, then shoot 2k clear over the lot.  Came out really well.

I also cleaned, primed, painted and clear coated a whole heap of doo dads including swingarm, airfilter cover, brackets etc.  I now have everything painted either by powder coating or by 2k system. All in gloss black.  I did the swingarm myself as i didnt want to remove the rubber bushings which can be an expensive and hard exercise. 

First pick below of the parts now painted.  The rear guard is the only panel which is not original. It is from Re-Mx.  The tyre pressure decal is in the correct location on the back of the rear guard.  Lot of folk get this wrong and put it on the chain guard. This was true for later models, but for 74 it was on the rear guard.

(https://v0fisq-bn1305.files.1drv.com/y4mQKgl7882L-HvRERb0cXWJwPjsCAgzFoiQJN8tnn8IgGLlVC_MPHcmf2o4KaQtm5GUYU6om9SefwtqjazF7wD4SvBQHoPGYhUOgCpJkgWjd1VoWNxrTzZqZTKtIN-BziVYk4JtXpJmboXeUkGDhlzY_9HIP_2xVySLDy5L9j0aa1PaMk-mDlVwQpAHSLK_4QLcPR1c7zOicbNj3GaJCysEg?width=660&height=371&cropmode=none)

Next pic is of the seat and frame.  The seat base is steel and was pretty corroded.  I got that blasted and powder coated.  It has a new seat foam and cover period correct. The frame was powder coated and the metal decals re-applied.  You can still buy genuine frame decals from Honda.

(https://wefisq-bn1305.files.1drv.com/y4mz9CF6dUnhX1FujmMu4rIat26o4l_tZ7r9vC3u8rdw7p9KJU33Y6mffHrtPpO2p829YWx0bQOigYrPGrPn8nmg8BqiMUtBkYKkRxYfiom_TDM8SjoCP3xQkFXhfiLkldVc73MPt4dl5dXpfrVxTl6MCbkNEl9d28DIWivs0UKX2bda_-WNu3yM28Zs8PItw2OLPJ13zsidyA9CGzXANFHpg?width=660&height=371&cropmode=none)

The last pic here is of the frame steering stem. The powder coaters did a top notch job.  The XR was basically on the border of being a basket case with its snapped peg mounts and just beaten up appearance.  The frame however was in surprisingly good condition.  They blasted, zinc primed and gloss black powder coated the frame, airbox (not airbox cover), pegs, peg mounts, bash plate, seat base and some other brackets.  The decal is genuine Honda for this model.

(https://wufisq-bn1305.files.1drv.com/y4mgt9SCVu5ATty6UhyBtvSYw-AOql9gIU-DFLL_y2BmgOhgxLLFylYp2AwHr35kfG9YEgpPnY9e2j8g_S8TnCsFfPyb8e1wc_Et8UrZbbp9kPPysd3-WGk5ivtAHY_xhScKM8IIkqV1VNbz8cFgtT8N1PvHtDXlleP5a3hqu0RE1qxdbLzQFaujjRizebI3_8D78Gig7QCpjNmj75TKl5lgQ?width=660&height=371&cropmode=none)

I pick up the engine on Tuesday.. but start work again on Wednesday.  Looks like i will be slowly assembling the entire bike over the Christmas break.  Most of the hard work is done, and soon it will be time to just clean, check, grease and assemble components.

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: Big Scotty on November 24, 2017, 07:24:44 PM
Gray Alex
I replaced my head stock bearings with a all balls tapered roller bearing kit,came with seals and fitted perfect,no modification needed,disregard this comment if you have did it already,looking good????
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on November 24, 2017, 07:47:17 PM
Hey Scotty,

No, i have not done that mod but it sounds like a good one.  When i took the XR for a test blat, the steering was fine.  I disassembled everything and it was clean and OK.  All i have done is order anther 10 ball bearings (i think there are 42) just in case some went rolling off or are knackered.  Clean her up, plenty of grease and she should be good to steer for another few years...

Cheers,
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on December 05, 2017, 10:48:39 PM
I am working away at the moment, but picked up the engine from Richard at Pipe Kings before I left.
He did a good job of repairing the broken engine footpeg mount. The left mount in the pic was completely snapped in half.
The other repair with all the meat on it was there when we got the bike.  We couldn't repair that one, for fear of creating a leak from the gasket. (it doesn't leak oil at the moment believe it or not)
For now we are just getting the bike up and running properly.  In a few years when I tear the bike and engine down, we will repair the "repaired" weld to take it back to original.

(https://wufdhg-bn1305.files.1drv.com/y4mLClDnHKTgMwkSxQXjHQykWVWLZSvbOUDPL5-PAmyd2bxDvi-HC2bP3HfaUzQNN1opglD85vRwAUMM-_Rmhi3NdAaFkLQz4DrRGPmW1zXmPrfVFt1oTBFkAWb7dF4i9NATPwxnqjhltXEH7AM6xE8vtZUjQMoywYPVnQr0qIJudHyEQuwmwb6WR2LweF30snri81HodwU-QoNzMtT_7IPFA?width=660&height=371&cropmode=none)

I should get the spokes soon and a few other small parts.. then its a bit of paint, cleaning, greasing and start the assembly process which will be fun.

Cheers,



Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on April 30, 2018, 04:35:19 PM
Been a while since i updated the build.  Have been busy with an XJ Cherokee project.  Anyway, it was time to get back onto the motorcycles...

I have most of the parts, so it was time to reassemble the motor with some new gaskets and seals, and a new shift shaft. I used new Honda nuts, bolts and washers and fitted the engine back up to the frame.  I assembled the powder coated pegs, mounts etc to the engine and it all fitted up well.  Hopefully, the tig welded and machined mounting points for the pegs will hold up well.

(https://vbbv6w.bn.files.1drv.com/y4mwGw4E62cNGs-TdT-rZ0KShBtSgFL0kTBdgOzLUxO-06_zkQcUIOhJPe_BwiHYqO9e4wpQ_UWAJzEX6bM4MclcNKbHm20HfNDmKt0LtRkj9L4X_dob81w7EFuUUHHx2s9nzkFsKKtcOUPW8yXYoRc5WQ_VV8NWmPSNBSJzQxEzDMBZyvr4ToumfP4vfr2mFovrl8klCuP0VfcIeOSS_Nzbw?width=660&height=371&cropmode=none)

(https://w7bv6w.bn.files.1drv.com/y4mN05Coer9hzPdxpClXikHKExCyzP8y3VX6ByxSwn4u4YIk0EMd9_eawKWX0ZeQxkkS_-V1TSfogE357noXqiM475_tywCoggJ5QKpzvWupkdQwzHqP16j5jklhcAXGu3IZSMgOeRyl154x2vxSmZTYzYjOFmPBc-tULaTRTEUuKbawcyZzw30hvkCehhFdUUaRT5v_4zofnnBhLVM3AGgRg?width=660&height=371&cropmode=none)

(https://wbbv6w.bn.files.1drv.com/y4mwX1ULv8IFh9V8WAx4-fRxrLZz4Wqarw59yW3u9VgxjbVzUY9SBFUiYruToZwd_OKJhJ4aZB8LEYKSkZG5yLZfQGlyHQqXvgnZg76AnPdZcgdIJx2i7V0ab-iAQoV1u-mReX9Ks0PdhSEaXwq861LRhNLstnSD8pTTwlOsPPKSChKTvEnr1pE9yoDmMFLQrKmnPkHDNExBT2-0myUQYREFw?width=660&height=371&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: skypig on May 01, 2018, 08:30:17 AM
Looking good.
Just a little bit jealous
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on May 26, 2018, 06:32:31 PM
Thanks Skypig... yes, she is coming along nicely.

I found a bit of time today to tinker, so i played with the XR and got the suspension on.
The front forks were rebuilt with new seals, oil, sand, buff, polish etc..
The rear shocks are Re-Mx replicas.  I even have the OEM style decals to put on the inside bottom of each shock.
The steering was cleaned, bearings replaced (42) and greased/adjusted.

Seat cover is the correct 1974 style. The cover and seat sponge are new Re-Mx items.  The base was blasted and powder coated.
 
Nearly everything so far has been put back together with all new genuine Honda XR75 hardware.

(https://6io5sg.bn.files.1drv.com/y4mkwKamwwT0NSnqujPZVa-CI6z9EQWxO32TygX5L3GL9WWI-fKb4gH3bpi1AaNYxogTnv7QcBQHenVihXba4IDIX1Q3E1m2ea4CvwdI94tkzSImBHusOIJEYIvBL6Ly0LzPSBDBNyFtd6u9x1BeBkrhO3QNe956SzlBHjs5RfubpUAUZKezcM1gzpSRyU6jFKLX11J3wxqHJgn_XBxf-psvQ?width=660&height=371&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on May 27, 2018, 09:24:59 PM
Having a bit of a push on the XR at the moment. 
I had previously polished the hubs up.  Now i decided to lace up the new rims and spokes.  Spoking wheels has me scratching my head sometimes when i dont quite get it right, and have to try again.  But in the end it all comes up well.
These XR wheel sets are now ready for truing and then fit up of tyres.

Before...

(https://im07gw.bn.files.1drv.com/y4mQdth1iMRUe0awD6dT7FQl3oxFbBNy15M9CKwqCSS046-KLEQdVc3xEPnPubjJJBnzgqK_VVpG4NoulfLwvtylRibr06lD-RrxTZYdcBJe9GCs-M0jHFHHeIdgJT8fniscPxvxpraq1SxDRcnVb0oXeXm2rxA8-b467eYDyv-SaTgcbUVY-Flb9kJOmolsLQdfK24cF_a-x7l6Sm8UZ66tQ?width=660&height=660&cropmode=none)

After...

(https://8yqe1q.bn.files.1drv.com/y4m8GrZ0QDRSIEVmEarAELf4Ru-XVu3yMYAjiraKbK5T32q2KHUArz5SS78_whnZNKJoYLFp1WAdzdrWWLXxigI3L46_WYy7vlb0OZzXOQCOlc3bneHa0BiGDCfWOnrRXXBst6QcKB6ijhHNarN5piJmg-CFUCjxKg_60d9QGsxs3se4jKIlc9hh_jVzNLv4oTMTAj4Lr-AhxxnIpBH7Qywgg?width=660&height=371&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: 80-85 husky on May 28, 2018, 09:49:46 AM
nice work as always... shiny bright things... ;D
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on May 28, 2018, 05:21:56 PM
Thanks Husky, i am like a Bower bird.. seems to be attracted to bright and shiny things.
Going to get myself a decent wheel truing machine.. i have a lot of wheels to true, and also i cant find the one i made out of wood...  :o

Had a bit of spare time again before i go back to work in a few days.  Got stuck in and it was actually pretty good fun ripping open Honda packets and taking out shiny new nuts, bolts and washers.

Got the airbox back together and even have a new sponge filter oiled and fitted.
Buffed the bars and refitted those.  Did the old school trick of whittling down some broom handle and packing it in the ends of the bars for bar stops... mum used to go nuts when i was a kid.

Refitted the levers and added the rubber end doodads..
Cleaned and refitted the ignition coil making sure i buffed off some powder coat so i got a good earth.
The new front number plate and cable guide was fitted.  Perfect match thanks to Re-Mx.
Also added the silver decal to the swingarm and bolted the chain guard back on. All new Honda nuts, bolts and washers in the correct lengths.
After market carb was refitted and a new boot band added. I have run the bike with the new carb, coil, points and condensor and she purrs...

(https://8sqe1q.bn.files.1drv.com/y4mA4OVPHIF0l1wAZMpDLrUdBJl99iXLO_buaG6HPm3cyuiao8oB_tTKNkXIllH3PmaZX_EuKXixXBIbrhXrIm1j_18FYRYbZAsmewu7Nx1IsvDUx7OyZyKOfe9dOP9SkSnIOSMJggboka4PmqArE3FI-nPiJpWLPsJHkAGzdWB0zk515cM8NFb7OjfTO2uaA3HyGCm9esx1eOQLo1LOwd2ZA?width=660&height=493&cropmode=none)

(https://8iqe1q.bn.files.1drv.com/y4mikISRY6VTLcfz3fALReUD0NjdjXABzfuu7JIRjKatIwlWVHXNEAczl5tXjeY4io2v1TtJai3HPCLunnuoCevgBWxnM2KgDMrNUGAu6PYUaoLq7pAe_88WVfZli-BzIeDnPK0xfRivslPVEcJyCSzSB2w2GHLhGdk-QI13hPme3RVi61NkihrKrKACo027ZNDgjrTsHOHoeOsdkEk1wHcKQ?width=660&height=371&cropmode=none)

Still have to finish putting decals on the tank and side covers and then shooting some 2-pack clear over the top.
This old girl may be running in a month or two!!

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: PERM250 on May 28, 2018, 08:05:36 PM
LOVE WATCHING THE LITTLE XR 75 COME BACK TO LIFE GREAT JOB ALEX
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on May 30, 2018, 05:41:29 PM
Thanks Perm,  its fun working on it.  Especially now that its all clean and you can just spend time tinkering and slowly bolting it back together.
Wont be able to do any more for a few weeks due to work commitments, but got the decals on today.
Bit of a learning curve doing these.  The first time i tried it, the decals blistered due to the fact i had not let the paint dry for the recommended 1-2 weeks.  They also bubbled as i put them on dry.

This time i read the instructions first...

So, get a squeegee, sticky tape, measuring tape, spray bottle of water with a drop of detergent, your measurements and some towels.

I had previously scoured the clear coat so that the decals have something to bite onto.
I measured everything up and used tape to locate the decals.  That way, you just peel the backing off and apply them and you have already done the hard work of getting them in the correct position. So peel your backing off the decal, spray water around the area and gently apply while using the squeegee to remove bubbles.  Once done, you can remove the top decal layer and you are just left with the decal.  Give everything a bit of a rub and then stand back and admire the job.

(https://6yodyq.bn.files.1drv.com/y4mnOc-0-c5i-ldvNYUSt2-K-l2KRImlCnKJDvxTrJD4qfkHzLZzIJOHtovmQ0sYI5ztL06rWiYZtkg2qK5DPA9_h7ETT1nP9_WYHih3f320VCeYgA8J39jNPU1KKSl3ZV1eaV2LjM1yjg14kEEJiNESe9KhS9MUNxmpYc5cLExgQVvV2Nv0qiX8WEcLLBBoHR68YkX1AeaV3Gy7rrR6mGATw?width=660&height=371&cropmode=none)

Pic below of all the panel decals on.  I used measurements from my original tank.  Decals are from Re-Mx, Fastguystuff and genuine Honda from Partzilla.

(https://6iodyq.bn.files.1drv.com/y4mJFBzs6rlJl50wxjJnvrUS7BcXiywxGdw4lHccGyj6KMuQox8f73J_Kaw7kdRA-JBjIP8jojCDQKF5WBwoTnfwhYdRp-QjOhWjJFNKl-aoPT4GZTFFm6k6qF3Aj31zVQJRcIL76j5ztaQy2x0LnVj_KEfHBliVloG6t0e5IhIE8LpMy4Q3fVA4SVvti-eu31tXd8mWHv1SyGaH1cb0VDSXQ?width=660&height=371&cropmode=none)

In a few weeks, i will give everything a light clean and scour, and then apply a dust coat of 2K clear followed by some wet coats.  That should protect the decals and provide fuel spill protection for the tank.

Cheers,


Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on June 17, 2018, 08:50:42 AM
This bit of kit came in the mail the other day.  Box was ripped open, so i guess i am lucky no parts fell out.
Anyway, i stuck the wheel on it, and it took about 15 minutes to get it all trued up both up and down and side to side.
Hopefully i will get many years of use out of it, as i have a few rims to do and probably save a heap on tackling this type of thing myself..

(https://8yoyaw.bn.files.1drv.com/y4m36ZxswKgONqSe3oUyvBkUxK14HZpbpf5hxeUapAef0FIxxaeMEF59064Sz2zlxIO1ou9ICY_mSOhS1bvWAANXARJ0DGJqYap4aTEQVy5kTXzOsaXBzxskTdPdkSF-o60qhsblNPFCkaC24WWlBKCrY78Q4yHP8HZTmrBa3aSp9WJOEw82bwi4sB7escewAItcV8m29cBoKsjbf_W6t67cQ?width=660&height=371&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on June 20, 2018, 10:49:16 AM
I tried to fit the tyres up myself, but im hopeless at it. Have wrecked a few tyres before and scratched rims.
This time i popped the tube.
Packed it all up into the car and took it to my local bike shop.  They fitted new tubes and rim tapes and gave the wheels back to me in pristine condition.

I cleaned up all the spacers, backing plates and everything else, then greased the axles and slapped everything back together.

She is now a roller....

(https://8iqxjg.bn.files.1drv.com/y4mPRMXb5WXrmfGfl0YN7jpf9kH8yMQdGtfzsUOfT4RaXfQzy9PUpUM5B4_C_HYUCB0g8X99jmKzhFAElr8-0LZyLRoxRthqrRZ_sXPbXjIowt04AGlgyT36FVu_9tyUerR7REdIeuGTqb2kCcsSAmu559TKGzCf1Ss-URd8exCP6y8k5oz1byPLKIpApk0bZq7EfZ2XhtlatVeOrqNoylY7g?width=660&height=371&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on June 20, 2018, 02:36:15 PM
Bit of a push to get the old girl up and running...
I re-fitted the side stand and front brake cable. Everything adjusted up nicely.
I cleaned up the brake rods and arms ready for installation.

Was time to fit the power pipe up.  Fits up nicely and with a new exhaust gasket. I had it running with the pipe on before i tore it all down and it sounded mint.  Still gotta get the panels cleared in 2K, but the weather has been shit.
Also, the kick start will need a major look at, as it is sloppy as hell.   I think a little bit of tig welding on it and some grinding should get it back into a serviceable state.  I do have a new kickstart rubber for it :-)

Cheers,

(https://8cqxjg.bn.files.1drv.com/y4mJWQrfrpA7D4BXZBglMNFB4J6ZUj3ScD8FSCFZN6Yq3CXzcj4a3hehS9Zh2JHhT8dd_r6UcuNhe_Qc0-yj0yxkgc9VNPQX_rqJNH2xSZESdmbtVIIhSbqPpdDwPAfxalCNLprEbeR6vCe5-0LNdtsDZWZzmr0coQz3S3I_iljBpe2CnL0ORN6jNHrmvMgJ_ppzvuHgbk6QjfhYQvZAMDT6w?width=660&height=371&cropmode=none)

Title: Re: New XR75 K1 1974 Project
Post by: 80-85 husky on June 20, 2018, 08:09:17 PM
Maaaattee whats with the tyres thing...everyone who rides a bike should able to do a 5 min complete tyre change while knocking back a few cold ones..use a bit of tape on yr tyre levers and make sure the bead is in the well, SHimples... ::)
Title: Re: New XR75 K1 1974 Project
Post by: skypig on June 21, 2018, 08:32:17 AM
As I’ve mentioned before. Changing tires used to fill me with dread. Now I almost enjoy it.

The life changing event was watching (several times) Doug (previously Brigstone, now Pirreli’s MX tire man) show how its done.

Video 1.
https://m.youtube.com/watch?v=2S5FEMjHjlU

I bought a tire change stand, and 3 short levers as demonstrated.
Almost as good is a good old metal garbage bin with garden hose or plastic tube around the top edge for the spokes to rest on.
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on June 21, 2018, 03:47:14 PM
Thanks for the link... it gave me inspiration to try again.
I have had my technique all wrong.  I used baby powder, but no Windex on the outside.  I only have two manky tyre levers instead of 3 good ones.  And im not doing it correctly.
I just bought 3 spoons, rim savers  and one of those bead doo dads..
So yes Husky, i will knock back a couple of frosties and give it another go..

On another note, the XR is off the bench and rolling around the workshop.  I fitted the rear brake lever and got everything adjusted up nicely.  Cut the new chain to size and fitted it up and adjusted the slack. Adjusted all the levers like clutch, throttle and front brake so that everything feels nice.  Had to do a few mods to the exhaust and handlebar clamps to get them all fitted and working properly.
Then i had a go at the kickstart.  Its 45 years old, and if you had been kicked as many times as this chunk of metal, then you would probably be in as bad condition.  It ended up being the shaft was worn, so i tig welded a bit of meat onto it and ground it back.  New rubber, new locking bolt and she worked and felt like it was only 30.

There is a black plastic mudguard that goes under the back seat of the XR and helps hold the main mudguard in position.  It has a crack, so the mudguard that sticks over the back wheel kept drooping down.  I have to plastic weld that up and refit it.  Then, if the weather comes good, i can put the clear on the panels, install the tank petcock and fit the last of the stuff on.  A good nudge, and i could be a day away from firing her up..

Cheers,


Title: Re: New XR75 K1 1974 Project
Post by: 80-85 husky on June 21, 2018, 08:44:43 PM
3 tyre levers ??? >:( bloody cheats!
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on June 22, 2018, 09:21:57 AM
3 tyre levers ??? >:( bloody cheats!
Yep, im going the full Monty...

The black guard that sits under the seat and helps support the main mudguard on the XR had a 75mm crack in it.
I had my Kingchrome plastic welder up on the shelf which i hadnt used before.  I got it out early this morning and read the instructions with a cup of coffee.. then got cracking.
I made a v prep in the crack and cleaned up the area.
I filled the welder with gas, fitted the weld nozzle and turned it on to heat up.
I selected the provided black plastic polyethelene weld rod and inserted it in the hole
I had the heat up too high so the rod melted all over the hole.
Turned machine down and proceeded to weld.  Works well when you get the technique right.
It will need sanding down and cleaning up a bit, but should be all good to provide another 45 years of service.

I have a lot of other parts that need welding.  I have bought a bunch of coloured rods on Ebay, so hopefully i can get my money's worth out of it.

(https://9yqxjg.bn.files.1drv.com/y4m3UgPu496DkHJWAR19nfkBHbXjMltLvT5EjDOihUHKjvuhA1ac29wS_oTn0R_zdDVmpN5pGvc_odtHYNEtD_uYgS77A39phxfWEUYkl7PBmoNPiX5aMFHYORi038KcheKkqT51XjrIayP1Z_HjYAMvKg4jxdIjpZwIo3nsZpSD9Zi-ppewrDaeFg_jQSyGQqrbMQIZSblb8yxR0ZsBzf2_g?width=660&height=371&cropmode=none)

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: smalls717 on June 22, 2018, 10:44:53 AM
Hello Alex.. did you get the Plastic Welder from around the Rockingham area ?
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on June 22, 2018, 04:44:35 PM
Hi Tony,

Yep, Dixon rd, one of the tool places. Was on special when i got it. Seems to work good, and it comes with bunch of attachments for soldering and plastic welding.  Just gotta practice on some scrap first.  Even  comes with a bunch of plastic rods in black and white for a variety of different plastics... abs, pe etc..

Cheers,

Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on June 23, 2018, 02:18:40 PM
Almost finished the bike this morning. Got all the panels fitted back up and a new fuel petcock fitted to the tank and tested for leaks.
Only the fuel hose has to be connected and she will be ready to fire up.  That's for tomorrow morning when we have family coming over and it would be nice for everyone to have a rap around the park on the old girl.

But for now, it was time to take get her out for some pics....

This is how we got her last year.. very sad.  None runner, snapped peg mounts, welded gear lever and just about everything rusted, worn, missing, leaking, broken and neglected.  We decided not to do a full rebuild.  Rather, get her running, then strip her down and clean, replace, paint, adjust and give her a birthday so she can live to ride another day.

(https://ffd1mq.bn.files.1drv.com/y4mpbhIjPmR_FuHV7mhuAjhi072APvktuv813cGp_Dk6xcK8VpKJt0TmnIdfc5y9TaexrAJWkB2OAoG5yCo7sVuJQn4fAnUJXi32j-YG54NPBlcXYNdWqMSIgN7BqJES7wO2DT06IkSTxMW7bbQMrNDkxBBkUpK7ICstWru2T6-aaVuFWlFTslQ9oEQcGtNi0I-EAxjpyU_j1mdz4RERHnvew?width=660&height=371&cropmode=none)

This morning, the sun was out, and the bike took on a new lease of life.  Even the neighbor came out to have a chat and admire the old girl..

(https://9sqxjg.bn.files.1drv.com/y4m3akC3aPuYD3QJpsNVNwmG8HIMHXxNlQasOIFIVXNYmu025ZSK3qfOGqaGbXUHh2xgmMIohdiCUGvGxrd09bFDTRJEzs0q52MmYuT3Vlog8d2DGb1tkJt3Ped8-dR72NuFef-V27cgR0h2JhJiq4Vr135Ply20W6Cy-n_WWpK615N6ZCkHMyYEuOaUgqgHgEg5pOunR_b9K0jb_MsNwfv1w?width=660&height=495&cropmode=none)

A lot of parts were sourced as genuine Honda parts from Partzilla..

(https://9iqxjg.bn.files.1drv.com/y4mvmRJTEmeY0MO2A0UWU4fFDbi4M17tDW3TDYFYvWP5Lx7B4hkfFmz809Ob-F9opg5ExJLcjQdabjJTIknSdX8o_TUTqgzTZtxK0Y_kzs7MDS3NUsUwZuZjCRvA0xZEKtJyAW8MjHJ3ztOy3D-sFWyr2heJ-jggSadEvrSU2KP525HZ-OHJRXLfyKh4y2xDOj01DTbgH9EGdN1EVjlFxcz_g?width=660&height=495&cropmode=none)

A lot of parts were sourced from Re-Mx, who do a lot of genuine and reproduction stuff for Honda mini bikes..
Some stuff was sourced from xrminiracer.com, who do a lot of power pipes and stuff..

(https://9cqxjg.bn.files.1drv.com/y4muJkp23TkHsz7KknaI4DMusF95F_lbpRed_9TdLtjM84e3Exx_XyXD75I76hvdJJpLlsvnff9h4msBCS_rVRIoWfhgeew1ih4hDYmBoAaH-nNuEZ-2oKZJI9vW5z37hmaLUW-JXx1dRVjtP3ZD8CN1vS9N9G6BX2st3WYsO596KhJCJvCAa3_sym6dw0C530H-aplj3SWr9y0WFJuQT3gSg?width=660&height=495&cropmode=none)

The paint was matched with the rear mudguard that was under the seat and still had some perfect paint.  There is a hint of green in the metallic grey.  The panels are 2k clear coated to protect them.  Some of the decals are genuine Honda, and some are replica from fastguystuff and re-mx..

(https://8iqsyw.bn.files.1drv.com/y4mFPnwDTmjXNzNUzBXRxZX9bbhNzud5rcLBkTi5PSelXCBEq_ud0XY_SF8BnovEEOjOhajD2fU3EETrvYNuUokUZrOJAB38voYo_1bMmaJVzdGwPzqngPt0-C_RsNYiH-3yE9al5dSThnfiNZ98uNs6o7Oi341PjLt0PAEJNOtzCfnUTKstihw0LmJshTnD8D6l0PfoFtiAexZYC_1cA8LRQ?width=660&height=495&cropmode=none)

Rather than paint the engine, we decided to polish it all up.  We had to take the engine covers off anyway to replace the gear shaft and some seals and gaskets, so the buffing wheel was used then..

(https://8cqsyw.bn.files.1drv.com/y4mOckmUYTBdsw2GAG6JAI0xN86Z_iOiqvGcJCci8MDr6adbL1sgMzfKE1UQIiVAtDksIrt0cwomCe0ua7NOLG0LZKFD3hczYpxBsHKCiKinTjFYKuzHMgWrGB3RYI0HiQhfTg_RupthmPliZS26hTzTRC4qnlYzIZqDt1EIYCo7AOOp4IgEBdqj9-A-X62-IwVq0jLyenw9J6ZOWMKpAuq6Q?width=660&height=495&cropmode=none)

The forks were rebuilt with new oil and seals and then buffed. Sadly, the original rims were badly scratched up. They have been kept, but aftermarket ones from Thailand were sourced along with the spokes and nipples.

(https://6iqxjg.bn.files.1drv.com/y4mHXFAgr9Gn8ZtPbAiORdVSuvX2Kk3gYv0HZI5uiIKx4B34Zaoc-eVIN79i6lLzwTHOTVbjfFJKhd2G-xu1EUvvigV01hbLX1Z_bIrmJViDEKjaKQditdq-ml-2ZBumVmxyK1GmL3EHXVG11p4dkg9DcxAQsaOiBUfnM3UfYTzlJJgTdzlgM8waOtX9cGvWq8_8op-tA6xmfJwkHrEpEfkHQ?width=660&height=495&cropmode=none)

Levers, switch gear, throttle, grips etc.. are all original Honda. You can still source the rubber doohickies for the ends of the levers..

(https://8sqsyw.bn.files.1drv.com/y4mabdhjJL694BfNVNywEBI3EqwaXqV0OQK4823-eSzVPOj9geFFnlTv62jM4i1TScMPBgWOBTNRDYagMukMJ9Ooz5pETB76aAy-08y-PJsaFkAauGavlA7TVhkCupJAZ67lroUz0vFtxrc8YYvhyB7zbP0DHzlukWpbDNDjIrswwHVsreUnr5o5jU1CKA09ZqM3fSciQTGSnvHRzknjNzgAA?width=660&height=495&cropmode=none)

Warning decals are correct size, type and location.  My old tank still had the marks where the old decals had been.  Also, the tank still had the original Honda wings on, so the location was measured and the new ones replaced exactly in the original location....

(https://8yqsyw.bn.files.1drv.com/y4mi-5MzK8yV_NMLKNCUyk-ljoTDp2XkqSNcz0LlE8ZzbmZeuh0DomKtaSyYJVJsMditBytTfL2Ay8RXiqdSMVs0qg4SY4GJctjboq90h-_ST7xQR7G_4XH0IdfgSVGe9L6VMdxcZrHi0zdOWnCSwBtxSXF6LRHtkMD7wYudJIp0xLWzxDWCyN21_SBhVkGsNEyf9ncUE5i-LVH1jeumeBxxw?width=660&height=495&cropmode=none)

Aftermarket petcock is exact Honda replica.. and works perfectly. New reproduction shaped seat foam for the 74 was from DC Plastics. Thats a 74 seat cover on there.  The alloy engine mounts are from the same company who makes the power pipes..

(https://6yqxjg.bn.files.1drv.com/y4mhLLkVQiDmAulRVq6KcogelTnjeOyay1VZhhDEit2q76KOVJHT5KTOH94aaNtxRu0e-A3rxZ3_-04pd02Hh5-CkjqJjBd-bQxkTUdknm0dhRNfU4i92JJHgs5SL-FcZCMafxSywT7n4WfJkNM2jBB0e5Uqk3diQFlPq7e_0pE0qYxaF9mbfEIH_Wc0mV2L9QFnHQHE0jGWMvItecx02sWFw?width=660&height=495&cropmode=none)

And thats about it for now... hopefully pics to come of the old girl running.  Then hopefully the boy will be riding her in a few VMX meetings just for a bit of fun.  The old girl is not ready to fully retire yet!!

Cheers,


(http://)
Title: Re: New XR75 K1 1974 Project
Post by: Hoony on June 23, 2018, 02:33:11 PM
wow...just wow.

what a great resto, i really admire your work.
Title: Re: New XR75 K1 1974 Project
Post by: Mick D on June 23, 2018, 02:48:59 PM
Yes wow,, looking sharp Alex
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on June 24, 2018, 06:53:06 PM
Cheers,   and not only did it come up quite nicely, she runs well too.
Connected up the fuel line, added some juice and she fired right up.  The lad took her for a blast in the park and run her through the gears.  Everything runs as smooth as silk.  Clutch, gears, brakes feel like new.  Bloody Honda's are bullet proof..

https://www.youtube.com/watch?v=EV-QbG2s-5c&feature=youtu.be

Cheers,



Title: Re: New XR75 K1 1974 Project
Post by: 80-85 husky on June 24, 2018, 08:05:38 PM
a reallly nice example of the Marque that one! top job!! ;)
Title: Re: New XR75 K1 1974 Project
Post by: skypig on August 22, 2018, 08:36:05 AM
Wow!
Drool!

That video looks like a super 8 from 1973 - not a fun police/nanna in sight.
A dad enjoying a motorcycle moment with his son. Isn’t that illegal? (What if “something” happened?)

You have a fabulous collection of Honda Minibike’s.
Title: Re: New XR75 K1 1974 Project
Post by: YZ250H on August 23, 2018, 07:46:05 AM
Nice work Alex.  That looks awesome  8) 8) 8)
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 23, 2018, 10:06:38 PM
Cheers guys...
Seems Honda made a great collection of minis back in the day. XRs, Qas, Cts, monkey bikes etc..
Title: Re: New XR75 K1 1974 Project
Post by: b490 on August 23, 2018, 10:49:15 PM
Absolutely superb ;D   A cousin had a grey model XR75 , same but seemed to have a fatter tank . Might have been a bit earlier model ? . I  had a red (5peed) '76  XR75 . Great bikes , happy times  as kids racing around the local paddocks. 

 Well done on a fantastic resto.
   
 Regards  ,
                       Steve

Title: Re: New XR75 K1 1974 Project
Post by: 80-85 husky on August 24, 2018, 07:17:34 AM
My father took me and my gemini boss 80 to a track for a minibike race. i quickley had a firm grip on last place but managed to pick of a few dax's and all the decksons but the kwaka 75's had me beat and the outstanding bike was a new grey xr 75, nearly lapped me :o
Title: Re: New XR75 K1 1974 Project
Post by: alexbrown64 on August 24, 2018, 10:41:25 PM
Cheers Steve, and good stories Husky. I think I posted up a pic of a Gemini 80 a while back. One of the first bikes I ever remember seeing was a dax when I was about 12.
My first race meetings were me and my brother against two other brothers...all on QA50's...
Title: Re: New XR75 K1 1974 Project
Post by: skypig on August 25, 2018, 09:05:04 AM
Cheers Steve, and good stories Husky. I think I posted up a pic of a Gemini 80 a while back. One of the first bikes I ever remember seeing was a dax when I was about 12.
My first race meetings were me and my brother against two other brothers...all on QA50's...

The suburban “QA50 Cup”!
Title: Re: New XR75 K1 1974 Project
Post by: 80-85 husky on August 25, 2018, 07:23:14 PM
imagine the dummy spits from that little circus 8)