Author Topic: New XR75 K1 1974 Project  (Read 37792 times)

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Offline 80-85 husky

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Re: New XR75 K1 1974 Project
« Reply #60 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... ::)

Offline skypig

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Re: New XR75 K1 1974 Project
« Reply #61 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.

Offline alexbrown64

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Re: New XR75 K1 1974 Project
« Reply #62 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,



Offline 80-85 husky

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Re: New XR75 K1 1974 Project
« Reply #63 on: June 21, 2018, 08:44:43 pm »
3 tyre levers ??? >:( bloody cheats!

Offline alexbrown64

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Re: New XR75 K1 1974 Project
« Reply #64 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.



Cheers,


Offline smalls717

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Re: New XR75 K1 1974 Project
« Reply #65 on: June 22, 2018, 10:44:53 am »
Hello Alex.. did you get the Plastic Welder from around the Rockingham area ?

Offline alexbrown64

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Re: New XR75 K1 1974 Project
« Reply #66 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,


Offline alexbrown64

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Re: New XR75 K1 1974 Project
« Reply #67 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.



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..



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



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..



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..



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..



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.



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



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....



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..



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,



Offline Hoony

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Re: New XR75 K1 1974 Project
« Reply #68 on: June 23, 2018, 02:33:11 pm »
wow...just wow.

what a great resto, i really admire your work.
Long time Honda Fan, but all bike nut in general, Big Bore 2 stroke fan.    http://www.youtube.com/watch?v=XJoKP6MawYI
1985 Honda CR500RF "Big Red"
1986 Honda CR250RG
2005 KTM 300EXC "The GruntMeister" ( I love that engine)

Offline Mick D

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Re: New XR75 K1 1974 Project
« Reply #69 on: June 23, 2018, 02:48:59 pm »
Yes wow,, looking sharp Alex
"light weight, and it works great"  :)

Offline alexbrown64

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Re: New XR75 K1 1974 Project
« Reply #70 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,



« Last Edit: June 24, 2018, 06:58:13 pm by alexbrown64 »

Offline 80-85 husky

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Re: New XR75 K1 1974 Project
« Reply #71 on: June 24, 2018, 08:05:38 pm »
a reallly nice example of the Marque that one! top job!! ;)

Offline skypig

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Re: New XR75 K1 1974 Project
« Reply #72 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.

Offline YZ250H

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Re: New XR75 K1 1974 Project
« Reply #73 on: August 23, 2018, 07:46:05 am »
Nice work Alex.  That looks awesome  8) 8) 8)
Looking for YZ250C parts NOS if possible

"My inability to use emoticins in the right context is really getting me down :)
The only triple jumps he would have been doing are the hop, skip & jump.

Offline alexbrown64

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Re: New XR75 K1 1974 Project
« Reply #74 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..