The end...at last !

I got around to fitting the new parts to the bike this last weekend. The mirrors have really made a difference to the width and overall look of the bike. She´s really looks like a little motorcycle now. New fork reflectors, horn and rear fender complete that look. The carburetor has made a world of difference to the performance of the bike. She starts on the first kick and goes like a rocket (a 49cc rocket).  

As there is not much left to do on the bike besides obtaining one or two hard-to-find parts, I think it is safe to say that this restoration is now complete. 

I therefore will not be updating this blog any further.  

I have changed most of the fasteners on the bike to dome head stainless steel cap screws. I am still searching for a NOS R/H blue leg cover. If you have one to sell me please get in contact with me 

Finishing touches

My order from CMS has finally arrived with lots of nice parts in the box: 

Parts include : Mirrors , Handlebars, Fork Reflectors + Bases , Carburetor

NOS Carburetor Assy.
It even has yellow paint over the mixture setting screw. 

, Engine kill switch , Horn , Alternator cover and other small bits and pieces.

As rare as hens teeth

NOS Rear Fender and Leg Cover

More parts

I forgot to mention in the previous post that I have gotten hold of a NOS Rear Fender. This is an extremely rare part and I think it is safe to say that it could very well be the last new one in the world. Pictures to follow as soon as the said parts arrive.

 

School Fees

As luck would have it, I'm now in need of a new piston and rings for this bike as I have managed to destroy the last set along with the cylinder. During the past week i had the piston out of the bike trying to diagnose the cause of some pretty audible piston slap. The noise has been there since I rebuilt the engine and I was a little concerned that damage to the piston or cylinder might occur if I left it to carry on for much longer. With the parts out of the bike I measured them up and they were all within spec so back in they went.

I proceeded to start the bike up, let it warm up, gave it a quick rev and pssss..... DEAD. Why now ?

This is what happens when you re-use old wrist pin clips. The clip was actually embedded in the piston but i had removed it and filed down the burrs before this photo was taken. 

 

This is what also happens when you re-use old wrist pin clips. Those gouges are quite deep. I reckon a 1 mm oversize re-bore might just clean up the barrel.

In the mean time I've ordered a new piston and rings and with those "school fees" paid and a lesson learnt the hard way, I hereby vow never again to use an old wrist pin clip. Luckily I  have a good used cylinder that will be painted, honed and installed. 

I have subsequently learned that Expresses all have fairly loose piston to bore clearances, hence the noise I was hearing.