- Upon receiving the kit and first installation, the clutch plate was entirely jammed and had to be manually loosened with a hammer and screwdriver. Even after this, it remained stiff for probably 2 months.
- Lost the bucking bar accidentally not once, but twice. Also once lost the ball bearing. Both times I was several km from my house.
- Tried to install the engine backwards due to very low quality documentation.
- Rear sprocket alignment was very difficult and at first was installed incorrectly, once again, due to very poor manufacturer instructions.
- Chain too loose - Hitting frame, hitting tire, comming off and locking up the rear wheel, popping it in the process.
- Chain too tight - Locking on rear sprocket, occasionally comming off, but always locking the rear wheel.
- Engine alignment impercievably small degrees out - Chain grinding on teeth hard.
- Carburettor free flowing fuel out the overflow tube on the side - Probably a problem with the tangs, after several hours of adjustment was unable to get it to stop. Solution: New carb.
- Engine 'popping' (misfiring) (Unresolved)
- Very severe vibration (together with a speed bump fractured my finger) - Either chain/engine alignment or something loose.
- Chain throwing master link clips (3 times)
- Spark plug exploding out of the top while riding (Wasn't quite tight enough)
- Exhaust baffle and carburettor baffle both vibrating themselves off at the same time even though they were perfectly secure (probably from #9). (times 2)
- Fouled spark plugs x3
- Failed CDI x3
- Failed magneto due to bad sealing
- Stripped threads, lost bolts/nuts x100 probably
- Engine mounting threads including for exhaust all comming loose from their positions over time.
- Accelerator cable sticking either inside carb or inside jacket.
- Small piece of thread within the side of the clutch handle prevents clutch holder spring button (by design). Can't be entirely removed without force, vibrates itself back inside over time, causing the button to not work (usually when you need it).
- At the appropriate tension, the mounting point of the cable to the accellerator grip snapped off without provocation.
- Popped tires x3
- Clutch no longer working while both the exact same bucking bar and bearing are in place, clutch lever has full range of motion. Cable partially snapped but even manually it doesn't work. Broke while riding. (Unresolved).
- Extremely poor quality and dysfunctional chain tensioner - In my view entirely useless as mine regardless of how I adjusted it was barely able to even be spun by finger. No longer used.
- Chain seems to lose tension quite badly over time without the wheel moving/slipping.. I heard it stretches a bit so might need adjusting twice or so (once on installation, once after stretching), but I have had to adjust mine at least 4 or 5 times.
- The mounting for the accellerator handle requires extremely precarious use of a nut, which you cant hold by any fashion except to try and push on it with your finger until the alans bolt gets tight enough to hold it in place.
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Starting items:
- 2x bike frames - $110 (First build + rebuild)
- Bike engine kit from Starfire Bike Engines, Cannington - $200 **Highly recommend this vendor if local to you**
A full list of tools used and cost:
(Note: Started with NO tools)
- Adjustable spanners x2 - $15 (Poor quality)
- Flat head and phillips screwdrivers - $15
- Large pliers - $10
- Needlenose pliers - $10
- Grinder (Dremel clone) - $45
- Claw hammer - $10
- Drill - $25 (Poor quality)
Additional tools:
- Full set of ring spanners (4mm - 20mm) - $16 (On sale, decent quality)
- Small socket set x2 (For double sided tightning) - $40 (Worst tools ever made)
- Spoke spanner - $15
- Cable cutters - $25 (Good quality)
Additional / Replacement Parts:
- 1 New carb - $65
- 2 New CDI - $50
- 2 New brake cables - $20
- 4 New brake pads - $20
- 1 New trip computer - $40
- 4 Spark plugs - $40
- ~4 Cans spray lubricant - $40
- ~4 Cans degreaser - $55)
- 1 Tube synthetic grease - $15
- 1 Bottle synthetic chain oil - $15
- 3 New tubes - $35
- 3 Tire liners (Reinforced) - $15
- Replacement fuel line - $15
- Inline fuel filter - $20
Estimated total cost to date: $961.
.... And still, it is highly prone to breaking without warning, and is currently broken (on my way to work I might add) (See #9, #23 & #25 above).
Cheers,
Hajuu
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