Got the exhaust fitted, surprisingly without too much modification. I made a battery box too.
Handlebar switches on, all cables installed and working. Speedo fitted. Chain and sprockets fitted, with new sprocket cover that arrived from China this week. I found a new chain guard in my hoard. Rear brake installed. Started mounting the new wiring harness, voltage regulator, CDI and starter solenoid. I’ve ordered 350mm rear shocks (stock are 300mm) and a shorty rear mudguard and small tail light. Hopefully that will alleviate the fat rear wheel clearance issues.
CG250 Bitza build made good progress today. Got the tires on, wheels mounted, engine in. Some issues with front mudguard clearance, none, won’t go on, and I suspect modification of the rear mudguard will be required or some longer shocks. Tire is too wide to fit in the rear mudguard. Might buy one of them shorty AliExpress ones. Not sure about the inlet manifold angle either, carb isn’t anywhere near to being level. I think it looks ok so far though.
CG110 engine rebuilt with NOS cylinder and piston, head decarbonised and valves lapped. New valve stem oil seal too.
A quick coat of paint and it’s all ready for installation in the freshly painted frame tomorrow 😀 Beverley reckons I’m the surgeon and she is the nurse, passing me tools and holding things.
I like playing Doctors and Nurses with Bev 😂
Bad news. The Golden CG failed compliance because it was an insurance write off at some point many years ago. To get it road legal will require a repair certificate and it turns out that getting one is very difficult and expensive.
To move forward I’m going to move everything except the engine to a CG110 frame I already have. Unfortunately I can’t use the CG125 engine in the CG110 frame because it is more than a 15% increase in power. So I have to rebuild the knackered CG110 engine. I’ve bought a good used crankshaft and NOS cylinder and piston. And new gearbox bearings throughout. Should be a minter 😀
And the Chaly was mainly done. Still got to the get the horn working (handle bar button not doing its thing) and figure out why the front brake light switch is erratic (even with a new cable). Seems to go alright with the big bore kit, not fast but goes up the Wellington hills a lot better. Might not bother with a 70 head and bigger carb for now. Glad I left some patina 😀 Beverley thinks it’s ace, she’s been riding up and down our street this afternoon practicing changing gears.
Wheels back on and I got a new reproduction rear mudguard. Bev did a fab job of the prep work on the rusty old front one. It came up a treat 🙂 Cleaned up and painted the rear light housing too. We also fitted the new seat that amazingly was ordered on eBay from a Thailand seller on Sunday and arrived on Friday. Gotta love DHL!