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
October... The motorcycle is working fine, but its still with out the plastics .
Some of them needs only preparation for painting , others have cracks and needs to be repaired .
Searching for materials that repairs plastics , I found one magic (Greek - English) solution , I call it magic because it saved me, allot of cash .
Its one product , that haves two bottle’s , the first contain plastic particles , and the second one strong liquid that melts this plastic particles (not a simple glue) , in simple words I found a chemical solution , equal to , melting plastics with the use of heat .
I tested the product , and it did amazing work , the brand called as BORO PLAST ( Bonds all hard plastics in a minute ), free joy ... costs only 7.50 € (Cyanoacrylate ester and modified PVC ).
I started by removing the decals , and doing basic preparation for painting , I am very happy , because I have find in advance, all the solutions , for the problems that I have ahead of me .
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
Translation ... At this point there was a large cut (missing plastic) , no more !!
Translation ... At this point there was a damage in conical shape , now its filled with new plastic , its redrilled , and completely restored !!
Translation ... what a joy , redrilled , and completely restored !! 100% success ..
OK plastics are ready and send for painting , when you will see them again , they will be ready for use .
Next step was to rebuild the drivers seat cover, no I did not make it my self , I found one good man locally, and for one fair price of 25€ , he did the job .
The design , was my request , the result speaks by it self, the driver seat cover , is made by two materials, the most important is the top one , with the non slip surface .
Fighting the rust !! and more ...
The motorcycle is all ready in use, for one month now , It is still in the testing period , actually I have predefine that the testing period will be as two months .
The vehicle under this testing period , gets inspected from top to bottom , every three days.
Every bolt , brakes system , fuel system , frame , engine , .... everything gets inspected .
The only accident, that happened in the first month was the loss of one metal pin , that joins together the rear brake pedal with the pump's rod , I was in motion, and I realized that I lost the back brake, this pin was secured by a second safety pin, that probably was defective , and the loss of it, caused instantly a bigger problem.
Other than possible mechanical problems , the motorcycle is continuously checked for rusting parts, the last two weeks was very rainy , and I was waiting to see , if I will have problems and were, I need to be sure that the motorcycle is totally healthy and weatherproof.
The problems that I find was few, thanks God , some screws that I had polished with a rotating metal brush , started to rust , Honda uses one green coating over all metal screws, the metal brush that I had use to polish them , looks that it removed the old rust and this coating , and the screws started to rust again.
I did found in the local market, aluminum screws coated with chrome, and I replace the damaged ones with them .
Another problem that I found was rust on the main rod that connects the the brake pedal with the pump, I had to remove it , clean it , and cover it with one special plastic insulating tube, that gets shrink with the heat .
This cure looked to be the most suitable, as this rod become completely waterproof.
BRAKE SYSTEM FIXES
Adding some foam pads on the swing arm , was necessary , because I wanted to protect the clear coat on the aluminum swing arm , because it started to get injured by the contact with the brake hose.
18-10-2007
Finally the paint work on my plastics is done!!
19 of October , I was riding my motorcycle, so to get at my home, one car in front of me, with a woman as driver , did one emergency braking , and I had to follow too .
The front fork, did a dive all the way down with force , and all this caused damage on my left fork oil seal.
And It started leaking badly, I did a total rebuild , but I did not touch the front system at all , other than exterior improvement's .
I was devastated , this damage caused to me, to spent even more money , and my cash flow was all ready at the bottom .
I had to rebuild my front boots, but I knew that in order to make a proper job , I would need Oil seals & Dust seals & new springs & new Oil .
I found high quality Japanese fork Oil seals in Germany, at www.louis.de , the brand called as “Saito” , dimensions 37X50X11 .. Part No 10042200, this fork oil seals is good also for all this models .
HONDA NX 250 (MD21)
HONDA NX 250 (MD25)
HONDA VT 500 C (PC08)
HONDA VT 500 E KARDAN (PC11)
HONDA CX 500 E EURO (PC06)
HONDA CX 500 T TURBO (PC03)
HONDA FT 500 (PC07)
HONDA VF 500 F/FII (PC12)
HONDA XL 500 R (PD02)
HONDA CB 500 (PC26)
HONDA CB 500 /S/CUP (CB500S) [BJ.96-00]
HONDA CBR 600 F (PC19)
HONDA CBR 600 F (PC23)
HONDA CB 650 SC (RC08)
HONDA CX 650 E (RC12)
HONDA CX 650 T (RC16)
HONDA GL 650 D (RC10)
HONDA VF 750 C -C-E-D (RC09)
HONDA VF 750 S (RC07)
HONDA VFR 750 F (RC24)
HONDA VFR 750 F (RC24/88)
HONDA CB 900 FB (SC01/81)
HONDA CB 900 FZ/FA (SC01)
HONDA CB 1100 R /SC08 (SC05)
KAWASAKI EN 500 (EN500B1)
KAWASAKI GPZ 500 S (EX500E1)
SUZUKI GSX 750 ES/EF (GR72)
The hard part was to find the Dust seals , In Greece the official Honda spare parts channel , was totally dry .
I found the parts in Netherlands , at the www.cmsnl.com , part number 91254-KR6-003 , 9€ its one.
Because the shipping cost was very high , I ordered and other parts , so to have them as spare .
1) In total I got from www.louis.de one set of fork Oil seals for 10€, and two spark plugs NGK IRIDIUM IX CR9EHIX-9 ( was on special offer 13€ its one)
2) One set of WP springs , and oil WP 15 SAE . .. 117€ (got those locally)
3) And from www.cmsnl.com
SEAL,DUST................................91254-KR6-003 Quantity: 2 Price: 9.00 EURO
BRUSH,TERMINAL................31201-KS5-901 Quantity: 2 Price: 13.00 EURO
RUBBER,SPEEDOMETER ......37221-KW3-610 Quantity: 1 Price: 9.00 EURO
PLUG,PIN .................................45203-MG3-016 Quantity: 1 Price: 3.00 EURO
PIN,HANGER .......... .................45215-HA5-672 Quantity: 1 Price: 2.50 EURO
BUSH,PIN....................................45132-166-016 Quantity: 1 Price: 2.50 EURO
BOOT B ......................................45133-MA3-006 Quantity: 1 Price: 3.50 EURO
COVER,BAT.TERMINAL.........32411-KW3-000 Quantity: 1 Price: 4.00 EURO
LABEL,HELMET HOLD...............87511-323-670 Quantity: 1 Price: 2.00 EURO
PROTECTOR,MUFFLER ........18360-KW3-000 Quantity: 1 Price: 25.50 EURO
CAP,SOCKET BOLT.................... 91456-371-770 Quantity: 4 Price: 2.00 EURO
...........................................................................Total price (incl. VAT): 123.76 +Trans 40
Total 320,76 €
So far ... So Good ..
I have set the orders for the parts , but it looks that I will have to wait for two weeks until to get them .
I have rewind one piece of cloth on the left injured fork boot , so to absorb the leaked oils, stopping them from falling at the front disc brake .
The motorcycle have done so far 330 Km , and, it is time for the second oil change, my theory was that because the engine was second hand , I should do at list two oil changes by using cheap motor oil , so the engine, to get internally washed up , then I would use good quality oil (Agip 15-50W) and new filter , the first oil and filter change, was made when the engine was ready to be started for first time.
The weather starts to change , the winter is coming , I started feeling the need to add mud flaps , so to protect my self and the motorcycle from getting dirty from the waters on the street .
I started looking for solutions , and the first idea was to get one rear mud flap from Honda Transalp, unfortunately Honda asked me as 40€ , and I started looking else were .
I got a tip from one friend, that KTM haves them really cheap, and yes I got one for only 7€.
Another friend of my, gave to me one used rear mud flap from Yamaha DT , so I ended having two in my hands , I will see what will get were in time .
Right now I am very happy , that I got so far , I also got my new Jacket + Helmet + gloves , and finally I am in motion .
