New Non-KX Project

[umberto]

Where is the expansion chamber on that motor?   What are all those extra parts? 

[umberto]

So I took my wheels to Cycle Gear to get the tires put on. The guy tried to install them, got the bead broken, but was afraid to bend the wheels. I took them to Cycle Gear because I bent one myself. Should I try the Honda dealership?  I don't have the patience to do it myself. 

[81cr450]

Sandblaster may have your answer

http://www.oem-cycle.com/forum/viewtopic.php?f=4&t=816

As many bikes as you have I think in the long run it would be worth it for you

[umberto]

I bought one of those last fall, and I've been dying to use it.  Unfortunately, it does not help with tire removal, and the rims I have are unbelievably thin and bend if you look at them the wrong way.  I think I am going to just buy a set of rims off eBay and assemble them on the tire.  They are two pieces that bolt together with a removable hub.  Might as well take advantage of the design, I will probably never see it again, at leaset not on a bike I typically work on.   

[81cr450]

Duh nevermind , if I'd looked at the wheel first

[umberto]

I got my new wheel halves in today.  They are reproductions, but they actually have twice as many bolts that hold the wheel together.  Should make them a bit stronger:
 


I wish all dirt bike wheels were like this.  It was so easy to mount the tire!  You just put the tube in the tire, inflate the tube just a little bit, put on the valve stem side rim, turn over and install the other rim, and bolt together.  It took me maybe ten minutes per side.  Here is one of the wheels before I installed the hub:



And finally, here is the completed bike.  Kind of sad to be done, but it's on to the next one!

[Foxx4Beaver]

that thing couldn't look any newer....nice job.

[umberto]

Thank you sir. It was a lot of fun to work on. It brought back so many good memories of my childhood.

[81cr450]

Turned out nice , now your not gonna let kids ride that are you

Like to build something like it.

[sandblaster]

Looks GREAT!
I've had to use a heat gun at times to remove old hard tires.
Heat them till you smell them burning, then heat them some more.
It stinks but makes the tires way softer.

[umberto]

My son is 15 and almost six feet tall, and I can't keep him off of it.  He's such a careful rider, I don't mind him riding it.  He always helps me with my projects, so I have to reward him once and a while.  

You should get one to work on.  There are a lot of parts available and the bikes are fairly easy to find, especially the newer models (post 88 or so).  Plus they're actually a hoot to ride.

[umberto]

Looks GREAT!
I've had to use a heat gun at time to remove old hard tires.
Heat them till you smell them burning, then heat them some more.
It stinks but makes the tires way softer.

Thank you for the tip Sandblaster.  I'll definitely file that away for next time.  The tires were pretty stuck, but they were only part of the problem.  The stock rims were so thin, it was ridiculous.  You couldn't even touch them with a tire iron or they would bend.

[umberto]

Look what I finally got in the garage.  What a cool little bike!  It's all there, except for a broken throttle housing that I may be able to fix.  The motor has compression and fire, it just needs the carb cleaned.  I forgot how small it is (it's sitting in front of my 2004 KX 250).  I'll post some pics of my work on it tomorrow and a ride video if all goes well and it will haul my 15 year old around.  If he's too big, I may need to hire a new stunt rider.  

[umberto]

I was able to work on the Italjet today for a couple of hours.  I cleaned out the carb and gas tank, and changed the oil.  It is remarkable how good a condition this bike is in.  A put some fresh gas in it, and rolled her outside.  After about seven or eight kicks, it fired right up.  The throttle housing is cracked and won't stay put on the handlebars, but everything else works just fine.  Here is a video of it running.  I'll post more videos once I find a throttle housing and cable.

https://www.youtube.com/watch?v=ZecNyq2L1BI&feature=youtu.be

After we got it running, it got a thorough bath.  I polished up the tank with some light cutting compound and a fresh coat of wax.  It's such a pretty little bike when clean.  I'll be cleaning the seat with some leather cleaner tomorrow.

[umberto]

So I'm having a very hard time getting a replacement throttle for the bike.  The Indian/Italjet parts guy on the internet is not responding to my e-mails, even though that's how he says to contact him.  There wouldn't happen to be someone on the site that knows where to get a throttle housing for an Italjet would there?

This is the site I tried to contact in case anyone knows the owner.   

http://www.indiandirtbikeparts.com/partslistsandmanuals.html