THE HONDA AX-1
TOTAL REBUILD PAGE
Last edit 27 Oct09
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Mirror sites dhost.info/ax1/ Germany EU
By Kiriakos Triantafyllou Greece 2007- 2009
ax1rebuild.net23.net/ U.S.A
AUGUST 07
I have done several orders to deferent people , there is like a race against time.
Getting a new Battery, was also in my priorities , the final choice of what to get , took a lot of research .
And, I end up, to the new BOSCH battery's , at my region are the only brand at good price and has also 18 months of written warranty , no other brand offers that , not even YUASA .
No electrolyte inside ... the battery shows voltage !
From 1 Nov 08 this site runs on New server 1.5GB free space and more.
1000 Thanks to my new Free host .000webhost.com
Best view
1024x768
Page started 21/10/2007
Loaded with electrolyte... the battery at full power .
03-08-2007 Finally my first major parts order came at my door .
The rubber step , was the first thing that I replaced , the chrome metals got ordered too, the main metal axis , needed only some alignment , so I did it my self , and I paint them too.
Next step was to use my trusty glue , to mount permanent the rubber on the transmission lever , its the second time that I buy the rubber part , the fist one I lost it in the street (no gluing ) , so now I will not let this to happen again .
Replacing the fuel tank rubber grommets ( they hold the fairing) , after so many years the old ones was totally destroyed .
Rear brake pump ... washing - cleaning - painting - Installation .
Next step was the installation of the Regulator Rectifier ... The AX-1 had burned the original after 10 years of use in my hands , a mechanic friend of my told me that the one for Honda Transalp will do too ..... so I ordered one, and it did work well , the only problem is that is larger , and needs some extra work, to mount it .
I drilled holes at the bottom of the air filter box , and I did a very good work , now I have a powerful Regulator Rectifier ;-) made in Japan ... 70€ .
07-08-2007 I had a problem with the plastics of the fairing , the right side one was heavily damaged , so I order second hand replacement , also the front mud protector needed replacement too .
They send me from Athens two side covers in the price of the one ( 60€ ) , because both replacements had small problems . I also got one front mud protector for ( 30€ ) .
Here is all the gang :-)
In all this years small accidents had cause small damages in many parts , another example is the base for the mirror in the front brakes pump .
I got devastated when I asked prices for replacement pump , but I got lucky , I got as second hand from a local motorcycles repair store , a complete front system for AX-1 for 130€ ( wheel suspension - brake pump head lights handle bar - Km meter brake disc etc. etc. )
So I took everything that was in better condition from this set , and use it on my motorcycle , I also got some new parts , when there was no other option .
At 11-08-2007 one good friend, from a Greek forum , sold me , a second hand, one KAPPA Top case 46l , at 1/3 of the price ... I got very happy with it .. I started dreaming again and took courage to continue the work .
Handle bar - painting - and more ....
I had hard times to find a new handlebar for the AX-1 , the market is full of aluminum ones at high price (Racing style and glamorous ) , I was looking to do the job , but not spending money with out reason , so I got lucky again getting for free, one handlebar from Yamaha DT , at good condition, but with some rust on it .
So I did rebuild it, too ...... Plus painting with special spray paint for cars the brake pump, and the rest metal parts, at their original colors .
13-08-2007 I am working hard to finish with the installation of the electrical system , with the handlebar ready , now everything must to get in place .
I took me some time , but I made it , starter - lights ignition horn .... Plus the liquid cooling system ready for use .
At the first test , everything started working as it should be , this was a very big moment for me , my baby started to getting alive again !!!
15 of August Holy Marry save as , and protect as .
15 of August , afternoon 19:10 , all set for the first real important test .. Of starting up the engine !
The engine came as second hand , even if I had fix the exterior minor problems , I really did not aware if this engine really works , and if its a good one , or just an bad apple .
I installed the exhaust and an temporary fuel feed , new oil & filter , everything was set .
At the time that my finger was on the start button , I had with me two of my best friends watching .
I pressed the starters button , and the engine started running with out hesitation at all .
The idle RPM was almost at the right amount , and the engine was running smoothly , my God success !!! I could not hold my self and I started crying from joy .
There is no words that can describe my feelings , all the work that I did , all the money that I spent , turned to be well spent , and I , to be victorious after all .
Everything turned well after all , but the carburetor was looking to need some more cleaning and adjustments .
So I pulled it out again , and started the task , soon I find out that I need a special tool , to adjust the mixture .
So I invent one :-)
The cleaning with special carburetor cleaning spray , did the trick .
The adjustments did not took long time , the service manual was very helpful .
17 /8 / 07 The odometer of my motorcycle , looks to be in bad shape, specially the plate with the numbers , I also have a second odometer , and I decided to take both them apart, and make a good one , by using their parts.
The head lights , needed some cleaning too , but I found that one of my head lights was damaged , in the internal mirror , there was a small chink , at the spot , that the front plastic crystal joins with the main body of the head light , from this spot, moisture was getting in , and the mirror got damaged .
I took the best head lights from my collection , and I added special glue around them , so to double protect those too , covering any visible or not , chink .
I am not doing quick fixes , I do everything as to was this motorcycle, to travel until the moon .
The meter is ready, and cured quite well, I turned the odometer to 25000 Km , thats the kilometers that the second hand engine had make at the past .
So I am continuing count from the last stop of it, and on .
28 of August ...... I finally got one special clear coat , that I was waiting for long time .
I needed this clear coat to use it on the polished aluminum parts , swing arm , and front suspension .
There was a lot of discussion of who will be, the proper method , to keep the polished areas in good shape for long time .
The most known is to keep polished them , every few months , the other is the special clear coat .
I call it special , because not all clear coats do for this application ... any way .. this clear coat is from Standox Germany , I got the word of the local reseller , that this clear coat has almost equal quality and durability with the professional solution , of clear coat baked in oven .
Now I am finally free to fully assemble the the motorcycle .
This month was full of developments , I am very tired , and the summer heat does not help much , any way , I am just smiling by looking my progress so far .
