Distractions

Life's too busy to get much done on this scooter right now, but I got some time on on it before school, work, bike racing, etc got in the way. The frame and most of the smaller parts are painted. Still to be painted are: Sidepanels, legshield, floorboards, and front fender. Before stripping to the metal, the sidepanels looked very clean. After all the paint and filler was removed, it was clear that both panels have seen some time sliding down the road after an unintentional ejection. A little pounding and a lot of iterations of spot filling and sanding, and I think they're straight and smooth again.

The frame had some small cracks at the rear rack holes. Someone must have carried some heavy stuff back there!

The cracks welded up fine so the problem is gone. It's always good to go down to the bare metal on projects like this to see what we're really dealing with. After stripping, welding, and painting in new white, the frame looks really nice!

The motor is buttoned up all except for the top end. I still need to get the cylinder bored out for the 70mm piston before sealing up the top end. I was able to trade the SX200 gears for some TV200 gears so I can have all the TV200 quirks. Hopefully the stage 4 225 will provide enough oomph to push such a tall 4th gear.

The front hub is fully rebuilt. I was missing a few parts, and a little confused about how it went together. I eventually found the needed parts and luckily I have the working TV175 as a model. When I tried to take the TV175 hub apart, I found out that its disk is seized. I'll need to rebuilt that one too since one brake pad isn't really optimal braking.

The fork links damper studs were messed up. On one, the threaded hole was stripped. On the other, the stud was welded into the link. I was thinking about getting new links, but instead decided to weld up the holes and redrill and tap. Once that's done, the front end can be reassembled.