Well, it had to come eventually - but in our case it came two months too early. Due to circumstances beyond our control (sale of the building), we had to change our home on short notice. This required me to relocate EZ-RIDER waaaay ahead of schedule, like months ahead - so I was forced to move it to a temporary location until the new place was ready. (PLACE LINK TO VIDEO HERE)
One of the largest challenges I faced when rebuilding the Calipers from Hell was getting the hangar pin cover out. The hangar pin itself is threaded through the two brake pads that go into the front calipers, ensuring that they are securely fastened to the unit. Once the hangar pin has been installed, a pin cover is used to further fill the hole left behind. My inability to get the hangar pin cover out completely stalled the caliper rebuild for about a week, because I couldn't figure out a way to get the hangar pin cover out without damaging it to the point where I would need to do something drastic, like drill it out. The hangar pin cover is a proportionately large, wide and shallow screw type fitting that goes into the hole that is left over after the hangar pin has been installed. Its apparent function is to make sure that that the hangar pin, which has a recessed 5mm hex head fitting, doesn't get filled up with brake material and grime and resultingly difficult to remove. Why is the hangar pin cover such a problem? The main reason why is because the caliper body is made of aluminum, whereas the pin cover is made of steel. These two differing metals not only have different thermal characteristics, they also have electrochemical characteristics that give them a tendency to bond together, particularly in the presence of water.
The idea of a pin cover is a great idea, except for the fact that the pin cover tends to get seized in the caliper, becoming an even greater removal problem than the hangar pin itself. The removal of the hangar pin cover is further complicated by its design: It features a very wide and very shallow slot that requires a huge flat-headed screwdriver, of a size that most people don't normally have in their toolbox (9.5mm wide). So what people do is use a smaller screwdriver which then skips out of the slot, chewing up an already alarmingly shallow slot in the head of the screw. It only takes a few failed attempts to make the screw head useless, turning a bad situation into a horrible one.
Getting the hangar pin cover out of the front caliper is a very common challenge for people who restore older Honda motorcycles. There are many techniques around to get the pin cover out (Heat, Drilling, Impact), but the technique that worked for me was using a penetrating oil for a few days, then a properly sized screwdriver with a six-sided shaft, an adjustable wrench, and the strength of two men to generate a lot of torque, maybe 60lbs or 80lbs worth. That did the trick! Once I got the hangar pin cover out, it took just a few seconds (but an equal amount of torque) to get the actual hangar pin out. With that accomplished, I was faced with a choice: Refurbish or Replace. Ultimately, even though replacement parts are not terribly expensive, I decided that it would be more entertaining to refurbish these two parts and replace them only if the refurbished units didn't work out. That not only served to lower the cost of bringing EZ-RIDER back into service, it also provides people with an opportunity to see how they might refurbish parts that may be even more difficult to source than EZ-RIDER, which is not exactly an easy motorcycle to source parts for, considering it's the last edition of a small displacement model only distributed in Japan and the UK.
One thing I made sure of was to deepen the slot on the hangar pin cover by about 50% using a little cutting wheel in my moto-tool, to give the next screwdriver in line more meat to work with. I would also probably use a vice next time to secure the pin in place, or take it out while the calipers are still on the forks of the motorcycle.
Enjoy!
Help a Maker Out?
Did you see anything in this video you want for yourself? If the answer is yes, consider using one of the link(s) below to buy it directly from amazon.com. When you do, I get a small commission that keeps me going!
Bill of Materials
GLOVEWORKS HD Industrial Black Nitrile Gloves - 6 mil, Latex Free, Powder Free, Diamond Texture, Disposable, Large, GWBN46100-BX, Box of 100 https://amzn.to/35fifrv WD-40 Multi-Use Product Non-Aerosol Trigger Pro Spray. 20 oz. [1-Pack] https://amzn.to/30h2nmN Bondhus 22199 Hex L-wrench DoublePK,Long Length,12137 .050-3/8" & 12199 1.5-10mm https://amzn.to/2Ec80Zs Felo 0715750274 1/2" Series 800 Slotted Screwdriver, 8" https://amzn.to/365QQYO Trident Silicone Grease Jar https://amzn.to/38GjiDg Disposable Chopsticks, pack of 40 pair https://amzn.to/3979cLK Mazbot 6" Cushion Comfort Foam Grip Beading Awl https://amzn.to/2ZjDwOL 15 pieces Scratch Brush (Stainless Steel + Brass+Nylon), AFUNTA Curved Handle Masonry Wire brush Set Bristle for Cleaning Welding Slag and Rust,5 pcs Per Type https://amzn.to/2rvQFYK BLACK+DECKER RTX-6 2 Amp 3-Speed Rotary Tool https://amzn.to/2rHBJ9S Dry Wet Sandpaper by Heylure, 45PCS 9 x 3.6" Silicon Carbide, 120 to 5000 Grit Sandpaper Sheets Assortment, for Metal Sanding, Automotive Polishing, Wood Furniture, Wood Turning Finishing https://amzn.to/36AhUj5 Utopia Towels 12 Pack Dish Towels, 15 x 25 Inches Ultra Soft Cotton Dish Cloths, Blue https://amzn.to/34rdwC1 FIXKIT 7-in-1 Portable Workbench, Multifunctional Folding Work Table Scaffold/Dolly/Platform with 4 Wheels for Garage https://amzn.to/2QVtrVE
Finding parts for EZ-RIDER, a Japanese Edition of a relatively small displacement motorcycle (VT250CR / M29) has proven to be a somewhat "challenging" task. I find myself slowly being forced into the position where I must refurbish parts that I might otherwise prefer to replace, because my motorcycle is not as popular and accessible as other models. Case in point is the parts needed to refurbish the front brake calipers, which I believe includes the following parts: 1 064510-GE2-405 SEAL SET, PISTON 4 43353-461-771 CAP, BLEEDER 6 45108-ML7-922 SPRING, PAD (NISSIN) 8 45112-MS9-611 RETAINER 9 45131-ML7-921 BOLT A, PIN 10 45131-166-016 BOLT, PIN 11 45132-166-016 BOOT, PIN BUSH (NISSIN) 12 45133-MA3-006 BOOT B 14 45203-MG3-016 PLUG, PIN 15 45215-ML7-922 PIN, HANGAR Some of these parts are available - some not so. One part that seems to be a little on the hard side to source is #10 (45131-166-016) a PIN BOLT that functions as one of the two major caliper slide pins. When I took the front calipers of EZ-RIDER apart, this bolt was in absolutely horrible shape:
Well, seeing as everything is closed in Hong Kong and I have a need for this part to be serviceable, I took it upon myself to try to refurbish this part of the front calipers, and see what could be done to bring it back into service.
Enjoy!
Help a Maker Out?
Did you see anything in this video you want for yourself? If the answer is yes, consider using one of the link(s) below to buy it directly from amazon.com. When you do, I get a small commission that keeps me going!
Bill of Materials
GLOVEWORKS HD Industrial Black Nitrile Gloves - 6 mil, Latex Free, Powder Free, Diamond Texture, Disposable, Large, GWBN46100-BX, Box of 100 https://amzn.to/35fifrv WD-40 Multi-Use Product Non-Aerosol Trigger Pro Spray. 20 oz. [1-Pack] https://amzn.to/30h2nmN
Mazbot 6" Cushion Comfort Foam Grip Beading Awl https://amzn.to/2ZjDwOL BLACK+DECKER RTX-6 2 Amp 3-Speed Rotary Tool https://amzn.to/2rHBJ9S Dry Wet Sandpaper by Heylure, 45PCS 9 x 3.6" Silicon Carbide, 120 to 5000 Grit Sandpaper Sheets Assortment, for Metal Sanding, Automotive Polishing, Wood Furniture, Wood Turning Finishing https://amzn.to/36AhUj5 Utopia Towels 12 Pack Dish Towels, 15 x 25 Inches Ultra Soft Cotton Dish Cloths, Blue
As I strive to bring EZ-RIDER back from the brink of oblivion, part of the effort is to try to save as many of the original parts as possible. There are many reasons for doing this, but here's my top 3: - If you replace before trying to fix, you're doing it wrong - If you fix and then have no choice but to replace later, you're doing it right - if your fix means you never have to replace, you get to brag and get more stuff So, there's really no reason why I shouldn't do my best to fix as much of the front brake calipers on EZ-RIDER as I can, which includes (of course) its two pistons - each of which represents one of the most expensive parts of the brake assembly. The most difficult part of refurbishing the pistons was getting them out - they were completely rusted/seized in place and therefore extremely difficult to manipulate, with only about 5mm of their lip showing. Copying a technique I saw on YouTube, I used my channel lock pliers to pull them out, but there are some other techniques in existence that someone interested in following my footsteps may be interested in knowing: 1) Some people use piston pliers. There are specialized piston pliers available that use outward pressing force inside the hollow piston give a person a way to work them out of place. I have a pair of these pliers on order, but I still don't have the experience of using them, so I cannot speak to their effectiveness. One thing I know for sure is they won't damage the outer surface of the piston because they do not touch it. A potential downside is the fact that the clearances in the caliper are very tight, so they may not be usedful to pull the pistons all of the way out. 2) Some people use the braking system itself. They just remove the brake pads and then pump the brakes to use the brake fluid to pop the pistons out. This seems like a great way to get the pistons out, but I think it would probably be very messy, so precautions should be taken to prevent brake fluid (which is pretty corrosive) from flying everywhere. Still, this is a very popular method. 3) Some people use compressed air. They hook up compressed air to the brake line and use air pressure to eject the pistons. Putting a piece of wood in the impact area is a good idea, and if you have a multi-piston system, you need to figure out a way to work the pistons out in a way that doesn't eject one piston prematurely, leaving the other stranded in the caliper. 4) Some people use pliers on the top of the piston and just work them out as best they can, inflicting as little damage as possible aside from the lip area, because the main seal of the calipers is well into the caliper body. In my case I (1) Didn't have the pliers; (2) Had already taken the brakes apart; and (C) Didn't have a compressor, so I ended up using technique #4. Enjoy!
Help a Maker Out?
Did you see anything in this video you want for yourself? If the answer is yes, consider using one of the link(s) below to buy it directly from amazon.com. When you do, I get a small commission that keeps me going!
Bill of Materials
GLOVEWORKS HD Industrial Black Nitrile Gloves - 6 mil, Latex Free, Powder Free, Diamond Texture, Disposable, Large, GWBN46100-BX, Box of 100 https://amzn.to/35fifrv WD-40 Multi-Use Product Non-Aerosol Trigger Pro Spray. 20 oz. [1-Pack] https://amzn.to/30h2nmN Bondhus 22199 Hex L-wrench DoublePK,Long Length,12137 .050-3/8" & 12199 1.5-10mm https://amzn.to/2Ec80Zs Felo 0715750274 1/2" Series 800 Slotted Screwdriver, 8" https://amzn.to/365QQYO
Disposable Chopsticks, pack of 40 pair https://amzn.to/3979cLK Mazbot 6" Cushion Comfort Foam Grip Beading Awl https://amzn.to/2ZjDwOL 15 pieces Scratch Brush (Stainless Steel + Brass+Nylon), AFUNTA Curved Handle Masonry Wire brush Set Bristle for Cleaning Welding Slag and Rust,5 pcs Per Type https://amzn.to/2rvQFYK 40 Pieces - EPAuto 1/4-Inch & 3/8-Inch Drive Socket Set with 72 Teeth Reversible Ratchet https://amzn.to/2ROLnk6 BLACK+DECKER RTX-6 2 Amp 3-Speed Rotary Tool https://amzn.to/2rHBJ9S
I came across an interesting situation the other day. While removing the lug nuts on EZ-RIDER. One of the five lugs that fasten the sprocket to the rear wheel came loose, with one of the nuts attached:
I finally got the nut off after soaking the nut+lug in varsol overnight, using a pair of channel pliers and my impact driver:
With the nut off of the lug, the next problem became securing it to the rear wheel hub. All of the other lugs were secured properly, except for the one that had come loose. Not really knowing how lugs like this are secured, I had to stop and consult some experts. I looked online, but couldn't really find the exact right information, despite hours of searching. Ultimately, I considered using loctite to hold the lug in place, but then a stroke of luck happened! I was able to consult an older mechanic who lives in my neighborhood that showed me a simple and easy way to put the lug nut in. In the end, the solution was elegant and incredibly simple. He just put two of the nuts on the lug, tensioned them together and then, using the tensioned nuts as a temporary bolt head, tightened the lug into the hub with a wrench:
I have to admit it, it seemed so obvious after saw him do it, but I likely would not have thought of it without his showing me. So bravo to him! Thanks!
Enjoy!
Help a Maker Out?
Did you see anything in this video you want for yourself? If the answer is yes, consider using one of the link(s) below to buy it directly from amazon.com. When you do, I get a small commission that keeps me going!
Bill of Materials
GLOVEWORKS HD Industrial Black Nitrile Gloves - 6 mil, Latex Free, Powder Free, Diamond Texture, Disposable, Large, GWBN46100-BX, Box of 100 https://amzn.to/35fifrv WD-40 Multi-Use Product Non-Aerosol Trigger Pro Spray. 20 oz. [1-Pack] https://amzn.to/30h2nmN
15 pieces Scratch Brush (Stainless Steel + Brass+Nylon), AFUNTA Curved Handle Masonry Wire brush Set Bristle for Cleaning Welding Slag and Rust,5 pcs Per Type https://amzn.to/2rvQFYK TEKTON 24335 1/2" Drive Click Torque Wrench (10-150'.-Lb./13.6-203.5 Nm) https://amzn.to/2ROLlbY 40 Pieces - EPAuto 1/4-Inch & 3/8-Inch Drive Socket Set with 72 Teeth Reversible Ratchet https://amzn.to/2ROLnk6 BLACK+DECKER RTX-6 2 Amp 3-Speed Rotary Tool https://amzn.to/2rHBJ9S Dry Wet Sandpaper by Heylure, 45PCS 9 x 3.6" Silicon Carbide, 120 to 5000 Grit Sandpaper Sheets Assortment, for Metal Sanding, Automotive Polishing, Wood Furniture, Wood Turning Finishing https://amzn.to/36AhUj5 Utopia Towels 12 Pack Dish Towels, 15 x 25 Inches Ultra Soft Cotton Dish Cloths, Blue https://amzn.to/34rdwC1 FIXKIT 7-in-1 Portable Workbench, Multifunctional Folding Work Table Scaffold/Dolly/Platform with 4 Wheels for Garage https://amzn.to/2QVtrVE Best Value 24-Piece Master Combination Wrench Set with Roll-up Storage Pouch | SAE 1/4” to 1” https://amzn.to/2GyIU87 WORKPRO 4-piece Adjustable Wrench Set, Forged, Heat Treated, Chrome-plated (6-inch, 8-inch, 10-inch, 12-inch)
After I decided to remove the sprocket from the rear wheel, it was only natural that I would want to remove the front sprocket and the chain. Here's some of the things that I found out along the way:
Chain
The VT250CR chain is pretty high-tech. It's a size that's designed for a nice balance between weight and power, and it features some advanced technology to make it long-lasting. The VT250CR has a 520type chain, which means:
- There is a 5/8 of an inch gap between the side plates, to accomodate at fairly thick front and rear sprocket
- The teeth of the sprockets are 1/4 of an inch wide, so the gaps between the rivets on the chain are also 1/4 of an inch from pin-to-pin - The VT250CR chain features o-rings between the side plates and the rollers, which helps to reduce wear and increase the life of the chain Small Sprocket The small sprocket is also fairly high-tech, and it connects directly to the engine of the VT250CR and it has the following characteristics: - It is stamped 14T, which means it has fourteen teeth - It is rubber sided, to reduce rattle & vibration - It uses a very large diameter washer - It features 14mm bolt @ 40lbs Large Sprocket The large sprocket is a piece of stamped metal with the following characteristics: - It has a 80mm center hole - It is stamped 38T, which means it has thirty-eight teeth - It is secured by 5 Bolts spaced at 64mm This means that the VT250cR has 14:38 (7:19) gearing.
Help a Maker Out?
Did you see anything in this video you want for yourself? If the answer is yes, consider using one of the link(s) below to buy it directly from amazon.com. When you do, I get a small commission that keeps me going!
Bill of Materials
GLOVEWORKS HD Industrial Black Nitrile Gloves - 6 mil, Latex Free, Powder Free, Diamond Texture, Disposable, Large, GWBN46100-BX, Box of 100 https://amzn.to/35fifrv
After three years of being abandoned in the bush and who knows how many years of neglect beforehand, the front calipers finally surrendered to disassembly! When it came to these calipers, everything that could have been rusty was rusty. If it was supposed to slide, it was seized. If it was subject to rot, then it was rotted. Everything that could have possibly been perished was perished. In short, they were a complete and total mess! After hours of puzzling over how to get them apart, they have finally come apart, but not without some concerns: - ALL of the rubber parts that composed these calipers were perished - Everything that could have possibly rusted was totally rusted. - Everything that was supposed to move was stuck fast. The three hardest parts of the disassembly were: 1) Initially getting the mounting arm off of the caliper body 2) Getting the hangar pin cover out 3) Getting the pistons out In all three cases, damage to the calipers was very possible - and in the case of the pistons it may be the case that they are damaged beyond the point of re-use. My intention is to sand them down and make them smooth again with #600 and #1000 grit sandpaper, so we shall see how that goes in a future video But for now, enjoy the video of how I got the front calipers apart, which was a triumph in and of itself.
Help a Maker Out?
Did you see anything in this video you want for yourself? If the answer is yes, consider using one of the link(s) below to buy it directly from amazon.com. When you do, I get a small commission that keeps me going!
Bill of Materials
Bondhus 22199 Hex L-wrench DoublePK,Long Length,12137 .050-3/8" & 12199 1.5-10mm https://amzn.to/2Ec80Zs WD-40 Multi-Use Product Non-Aerosol Trigger Pro Spray. 20 oz. [1-Pack] https://amzn.to/30h2nmN GLOVEWORKS HD Industrial Black Nitrile Gloves - 6 mil, Latex Free, Powder Free, Diamond Texture, Disposable, Large, GWBN46100-BX, Box of 100 https://amzn.to/35fifrv Felo 0715750274 1/2" Series 800 Slotted Screwdriver, 8" https://amzn.to/365QQYO Mazbot 6" Cushion Comfort Foam Grip Beading Awl https://amzn.to/2ZjDwOL 15 pieces Scratch Brush (Stainless Steel + Brass+Nylon), AFUNTA Curved Handle Masonry Wire brush Set Bristle for Cleaning Welding Slag and Rust,5 pcs Per Type https://amzn.to/2rvQFYK
And that's an understatement! In actual fact, I couldn't even get the brakes to move, much less come off at first, because the rusting brake pad parts had swelled up against the inside of the caliper housing to the point where they were well and truly stuck fast against the disk. I ended up levering the calipers off of the disk using a flat blade screwdriver, then my largest BONDHUS hex key, and then finally, a plank of wood! When I finally did get the calipers off, BOTH of the front brake pads split away from their backing pad and dropped immediately to the ground! It was much more dramatic firsthand than it looks on video, I assure you! Still...enjoy!
Help a Maker Out?
Did you see anything in this video you want for yourself? If the answer is yes, consider using one of the link(s) below to buy it directly from amazon.com. When you do, I get a small commission that keeps me going!
Someone is HURTING the 12 cent motorcycle
=================================
In this video I discuss why EZ-RIDER urgently needs to be relocated - I found it on its side this
This was my very first online purchase for the 12¢ motorcycle.
A **HONDA** branded cover to both protect it from the elements and prevent BOTH the curious and the malevolent from messing with it.
I bought the cover on Carousell, an online marketplace that is somewhat like eBay here in Hong Kong. It was very inexpensive.
The cover turned out to be very nice and it was a perfect fit!
My first attempt to remove the spark plugs in EZ-RIDER ended in ignominious failure, with the spark plug socket I had purchased as part of a generic socket set completely the wrong size.
As it turns out, a 16mm thin wall socket is required to fit in the tight places of the 1997 Honda Magna VT250CR motorcycle engine, and I simply didn't have the right socket! The socket that came with the set I bought was totally the wrong size...it was 21mm! Not even close! So, after a little bit of a search on Amazon, I found the right socket - then I had to wait. Once the socket arrived, I was able to get to work. So I took the two spark plugs:
The copper grease:
And the 16mm thin wall socket:
and brough them all together to change out the spark plugs!
Post Install Comments:
Changing the spark plugs was actually pretty uneventful in the end. - The REAR spark plug is very easy to get at. - The FRONT spark plug is not easy to get at. You need to remove the radiator, which is a big job. I should have also removed the lower radiator mount as well, because it got in the way and for the little bit of extra work I should have removed it. But, in the end, the plugs were changed in under an hour.
Old Spark Plug Condition
For those who are interested, here's what the old spark plugs looked like:
REAR spark plug, FRONT spark plug
Lizard!
Though it has nothing to do with changing spark plugs, one of the highlights of the job was the lizard that's decided he's going to live in EZ-RIDER, and who made it clear that this bike was his now!
The lizard shows up a couple of times when I put the REAR spark plug and its boot back in, and I took some still shots that appear at the end of the video. Enjoy!
Help a Maker Out?
Did you see anything in this video you want for yourself? If the answer is yes, consider using one of the link(s) below to buy it directly from amazon.com. When you do, I get a small commission that helps me to keep going!
Bill of Materials
NGK (5666) CR8EH-9 Standard Spark Plug, Pack of 1 https://amzn.to/2Sb1Ocj LA-CO EZ Break Copper Grade Antiseize Paste, 1800 Degree F Temperature, 10 oz Jar with Brush in Cap https://amzn.to/2PerUZZ Sunex 884504 3/8-Inch Drive Thin Wall, Metric, Spark Plug Socket, CR-MO https://amzn.to/2MflpEq
