ZA50 disassembly!

some play in the con-rod from cookson on Vimeo.

My Puch City is a Cynthia!

So after all the work and replacing gaskets, cylinder & pistons the E50 died in dramatic fashion! All vitals were good, but when started it sounded like a bag of nails! We think that the crank is faulty and has come loose some how! The con-rod has a lot of play in it (left and right) which I don't think is normal! So........... Mopeds at dawn have bought a ZA50! The two speed model should give us some head aches but also should give me some real speed too!

One way clutch bearing!

This morning I figured out the problem I was having. When I pressed out the one way clutch bearing from the old drum I installed it backwards in the new one. Unfortunately I've damaged it now so ordered a new one from THEMOPEDJUNKYARD.COM

A3 clutch drum arrived!

My replacement A3 clutch drum arrived today. So I got it installed but somethings not quite right so I'll take another look at it tomorrow. On the left is the old mishapen drum and on the right is the new one with the refinished clutch installed. Oh yeah check out the new bars, same as Sinclairios.

Split, cleaned, New cylinder!

Split the case cleaned the remainder of piston III, the cylinder was scored so a new cylinder was ordered. The gaskets have all been replaced and also a new fuel filter. All In all it took 3hrs. Hope it works else it's a new engine!

YPV Spares what a service!!!

Had to get a new 70cc cylinder, YVPS delivered next day after placing the order, thanks Martyn!

The 17inch maxi wheels are on the Puch City!

So Cookson could not contain his excitement today and whacked the new wheels on! She is looking tidy

Sinclairio's wheels have arrived!

The 17" spokes maxi wheels arrived today. Going on the puch city ASAP!

New cluch material

The 2mm leather strips have stuck well to the clutch shoes after being clamped for a week. I just need to remove any access glue and give the leather a slight trim. It will then be ready for a test ride.

Moto-Matic have made a number of custom bikes for Supporo!

Sapporo Moped Creation from Rob Brooks on Vimeo.

Sinclairio installed his 3rd 45mm piston today!

Sinclairio's Ped from cookson on Vimeo.

Shop opening times!

When, & I mean when Mopeds at dawn have a repair &hire shop, this will be our opening times! Please take note!

The pistons have arrived for the puch city!

Basically the new piston has arrived but just because all the trouble I have had in the past I ordered two! This is the 3rd piston now. It will be installed on Saturday!

Happy Valentines to my Moped

Voltage regulator arrives!

The three prong voltage regulator with installation instrutions arrived today.

Clutch resurfacing!

So I used the clutch puller I bought the other day and look what I did to the clutch drum. It was a really poor quality puller and it didn't work correctly and dented the drum. Anyway I returned it and bought a better one today with which I was able to remove the clutch assembly.

Here is the second gear clutch with the cork removed, the three strips of leather cut to size, some gorilla glue, and a large jubilee clip to hold it together while it dries.

Here it is all glued up and secured with the jubilee clip. I'll leave it like this for a couple of days.







I was able to knock out the dents in the clutch drum as a temporary fix but have ordered another one from:

What mopeds can do!

http://www.youtube.com/watch?v=Xu2HMo63nyU&feature=youtube_gdata_player

May have found & solved the problem!

Basically as you can see I split the case after the scored piston and air leak which happened midway through a ride last Sunday. The case was split in about 30 mins as I'm quite familiar with splitting it. When inside, I found what can only be described as something that looked like a floor of a Blacksmiths work shop. Pieces of metal from both pistons sat at the bottom of the case! Anyway it's been cleaned out and reassembled ready for the 3rd piston of this engines very problematic start to its 70cc life!

Get to use my home made hub & clutch puller

Splitting her up again III

Just checking for any unwanted bits from the last piston, that could of been the problem!

Picked up a cool little clutch puller!

New chain splitter has arrived!

I bent my old splitter trying to shorten the chain on my tomos. The new one on the left although smaller looks the be reinforced to prevent it bending like the old one.

A35 clutch drum has been balanced!

Thanks to Steve @ NUBIKE for the quick turnaround.

Got my lights (half) working!

Spent a bit of time with all the wires out of the tomos today. I finally got the headlight and taillight working but I can't seem to get the brake light to work. Oh well this will do for the moment and at least I can ride in the dark now.

Ready to resurface my clutches!

Colibri forks sold!

My puch is a Cynthia

Well we rode for about 5 miles had a stop to take some pictures, set off again & the Puch cut out! Turns out its gone from turning out about 160 PSI to a measly 60 PSI after 23 no 24 kicks. Painful!!!!

Here's the damage to the Puch piston

The Good Life.........we gotta ride more!

The City is back!

Sinclairio decided to fit his old tank back on the city which involved grinding off the crossbar. But we both agreed it looks way better. He also fitted the 14t front sprocket and new clubman bars. This thing is mean!

Few more parts

More front sprockets arrive, received a 14 & 15 tooth also got a café racer set of handle bars!