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SX200, TV200 + LI150 bitsa

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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Mon Feb 03, 2020 11:21 am

Front hub was built up yesterday - really pleased that I didn't mark the paint!

IMG_20200203_080919.thumb.jpg.bd388810c3ee1cb7647a68e4838a601b.jpg


IMG_20200203_081041.thumb.jpg.6563273cb5cf6178c4d92700a49d413e.jpg


Forks next - not looking forward to it!
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Mon Feb 03, 2020 3:50 pm

Forks now built up and ready to go. As is normal, it was a bit of a faff, but got there in the end without doing any damage.

IMG_20200201_172347.thumb.jpg.d592468fca71da48ef3be8ac4a0f015f.jpg


IMG_20200203_131216.thumb.jpg.e925761c69c7ee5ea82558405840588a.jpg


IMG_20200203_131237.thumb.jpg.dba961c6325a87e3e2221aed012569e2.jpg
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Fri Feb 07, 2020 6:41 pm

A little more time was found for this today - petrol tank, tap and air box all found their way back on to the frame. 

IMG_20200207_160733.thumb.jpg.c8bf71a3ea5555453f0672ad573a0758.jpg


IMG_20200207_160537.thumb.jpg.bff16f128746e44abc68bc529c8e706b.jpg


When fully tightened, the straps were still slightly slack. This was remedied later on with larger rubber buffers. 
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Sat Feb 08, 2020 5:28 pm

Forks and handlebars now in position, I need to order in some more parts before I can get much further.

IMG_20200208_144317.thumb.jpg.2dce1e7bd1f10f4a3b6506def3bd6ced.jpg
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Re: SX200, TV200 + LI150 bitsa

Postby shane BBoys » Sun Feb 09, 2020 7:17 am

Looking good, I don’t see any cables I guess these are the bits that you need to order, will you manage to route them alright?

Cheers Shane.
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Wed Feb 12, 2020 9:26 pm

shane BBoys wrote:Looking good, I don’t see any cables I guess these are the bits that you need to order, will you manage to route them alright?

Cheers Shane.


Cheers! Shouldn't be a problem routing the cables - I always build my Lambrettas this way!
Grabbed a bit of time after a job interview today - wheels and hubs were built up with new tyres + tubes.

IMG_20200212_193236.thumb.jpg.c1782bcb3829a3cda4fa17c59aea9481.jpg


Then the dampers were sprayed up after being bare metalled yesterday.

IMG_20200212_193957.thumb.jpg.2cba0be4f60351592996c0a8bc8dad11.jpg


I'll hopefully be getting the motor in at some point in the next couple of weeks. :)
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Sun Feb 16, 2020 8:47 pm

Smartened up a few pieces after stripping them back to bare metal.

IMG_20200216_130316.thumb.jpg.5631199c85c51af2254937ae0d93887b.jpg


Made a start cleaning up the engine too. I'd originally planned a complete strip and rebuild, but theres nothing wrong with it, so a clean and spruce up will be fine for now. (gonna replace the carburettor though, the one on it is problematic)

IMG_20200216_131104.thumb.jpg.20d0a238a1d5441487a8d8b7dbef669a.jpg


Whilst stripping parts off to ease the cleaning process, I noticed that the gear shift tie rod was worn, giving a sloppy gear change. The elongated hole was welded up and re drilled, which should reduce the travel of the handlebar considerably during shifts.

IMG_20200216_145147.thumb.jpg.a6631ed31fc29dfcf35b1b6b9d2cd4ec.jpg


Totally regret scrapping the frame that this engine came to me in - would have been an easy fix for me nowadays!
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Sun Feb 16, 2020 8:49 pm

IMG_20200216_135431.thumb.jpg.a7a3bca45e6bc1e926f801014d6f3c80.jpg


Cables now ordered, as well as rubber trim + floor stuff! :D
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Fri Feb 28, 2020 5:58 pm

Start my new job on Monday. 8-) Its a lot less pay than my last one, but I reckon I can manage it.
Indoor job done today (far too cold in the garage) Number plate was stripped of paint.
IMG_20200222_144352.thumb.jpg.d3087e5605e34004cbff8c9a80675fbd.jpg

Masked up, primed, sprayed and buffed up.
IMG_20200228_164103.thumb.jpg.b7dea6a119d94f83027222da0de9a82b.jpg

Should hopefully be getting cracking with this soon. :D
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Re: SX200, TV200 + LI150 bitsa

Postby Knowledge » Sat Feb 29, 2020 3:19 pm

Good luck with the new job JFP, and keep posting those updates on the scooter. :D
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Fri Mar 06, 2020 9:33 pm

Knowledge wrote:Good luck with the new job JFP, and keep posting those updates on the scooter. :D

Many thanks! Updates should be coming a bit quicker now. 8-)
Motor now cleaned up ready to go back in - just need to switch the carburettor. 

IMG_20200306_160641.thumb.jpg.55ba1581332369c16876091da753b51e.jpg


Dived into the big box of new bits from Scootopia, and got a few more pieces fitted. Hopefully be getting the motor back in and cabled up over the weekend.

IMG_20200306_194625.thumb.jpg.31cfcde28709ab3255eb9ddc553df79f.jpg
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Sat Mar 07, 2020 11:15 pm

Got my polishing head on this afternoon, and smartened up the brake and clutch levers. They were a bit of a mess with lots of oxidisation, but cleaned up pretty well. 

IMG_20200307_162827.thumb.jpg.cc6707bd6a220a23401f317229b5d734.jpg


Finally got my act together and stuck the motor in this evening. 

IMG_20200307_204130.thumb.jpg.a3b23a6cd669e3334c7c7cef8b42b3df.jpg


IMG_20200307_204110.thumb.jpg.7204b9ff06b73bbf6d26d19e998c917e.jpg


Exhaust went back on before going for a pint.
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Sat Mar 07, 2020 11:17 pm

IMG_20200307_210124.thumb.jpg.7890191a2bce1a68dfc30265e292ccd2.jpg


Cables and wiring up next, should be making a start on that at some point tomorrow. :)
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Sun Mar 08, 2020 9:04 pm

Cables now roughly in position, I've ordered new trunnions for the gear + clutch cables, and new brake cable clamp/adjusters. I'll finalise the position of the cables once they're all buttoned up and adjusted. 

IMG_20200308_182156.thumb.jpg.9c0be49a9d6a0b70922ce04e1ff77d8d.jpg


The wiring is pretty much sorted, I just need to tidy up the routing above the rear mudguard once the regulator has been mounted. 

IMG_20200308_181908.thumb.jpg.bf1ac30d3debd05047af17640bf1c4c8.jpg


Looking forward to getting the bodywork back on at some point!  :)
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Sat Mar 14, 2020 9:59 pm

Cables now done up and sorted, wiring wired, and lights lit. Many thanks to Martyn for the wiring diagram. 8-)

IMG_20200314_195623.thumb.jpg.b39ae587cd11f9047f98d772ef6b33e8.jpg


Should get it running next week, then it's bodywork + trim time. :P
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Re: SX200, TV200 + LI150 bitsa

Postby dickie » Sun Mar 15, 2020 10:20 am

johnnyfartpants wrote:Cables now roughly in position, I've ordered new trunnions for the gear + clutch cables, and new brake cable clamp/adjusters. I'll finalise the position of the cables once they're all buttoned up and adjusted. 

IMG_20200308_182156.thumb.jpg.9c0be49a9d6a0b70922ce04e1ff77d8d.jpg


The wiring is pretty much sorted, I just need to tidy up the routing above the rear mudguard once the regulator has been mounted. 

IMG_20200308_181908.thumb.jpg.bf1ac30d3debd05047af17640bf1c4c8.jpg


Looking forward to getting the bodywork back on at some point!  :)

I've always tried to keep my cable routing and cable ties as per original but on my last build Martin cook (chiselspeed) advised me to use none on the clutch cable. When I look at my triumph 1050, it has none at all in the clutch cable, so it just finds it's own way. And when I think about it, all my big bikes have been like that.

I did this on my last build and it's a revelation. So much lighter than others I've done with same 5 plate and bgm spring set up.

I did think the cable might have hung out hither and thither looking a mess, but it doesn't.
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Re: SX200, TV200 + LI150 bitsa

Postby johnnyfartpants » Sun Mar 15, 2020 10:17 pm

Sounds perfectly reasonable - I'll set it free before the legshield goes on. :)
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Re: SX200, TV200 + LI150 bitsa

Postby Storkfoot » Mon Mar 16, 2020 12:44 am

dickie wrote:
johnnyfartpants wrote:Cables now roughly in position, I've ordered new trunnions for the gear + clutch cables, and new brake cable clamp/adjusters. I'll finalise the position of the cables once they're all buttoned up and adjusted. 

IMG_20200308_182156.thumb.jpg.9c0be49a9d6a0b70922ce04e1ff77d8d.jpg


The wiring is pretty much sorted, I just need to tidy up the routing above the rear mudguard once the regulator has been mounted. 

IMG_20200308_181908.thumb.jpg.bf1ac30d3debd05047af17640bf1c4c8.jpg


Looking forward to getting the bodywork back on at some point!  :)

I've always tried to keep my cable routing and cable ties as per original but on my last build Martin cook (chiselspeed) advised me to use none on the clutch cable. When I look at my triumph 1050, it has none at all in the clutch cable, so it just finds it's own way. And when I think about it, all my big bikes have been like that.

I did this on my last build and it's a revelation. So much lighter than others I've done with same 5 plate and bgm spring set up.

I did think the cable might have hung out hither and thither looking a mess, but it doesn't.


Thanks. I think I’ll give this a whirl too on my next build. I have thought about it before but never done it.
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Re: SX200, TV200 + LI150 bitsa

Postby coaster » Mon Mar 16, 2020 10:12 am

dickie wrote:
johnnyfartpants wrote:Cables now roughly in position, I've ordered new trunnions for the gear + clutch cables, and new brake cable clamp/adjusters. I'll finalise the position of the cables once they're all buttoned up and adjusted. 

IMG_20200308_182156.thumb.jpg.9c0be49a9d6a0b70922ce04e1ff77d8d.jpg


The wiring is pretty much sorted, I just need to tidy up the routing above the rear mudguard once the regulator has been mounted. 

IMG_20200308_181908.thumb.jpg.bf1ac30d3debd05047af17640bf1c4c8.jpg


Looking forward to getting the bodywork back on at some point!  :)

I've always tried to keep my cable routing and cable ties as per original but on my last build Martin cook (chiselspeed) advised me to use none on the clutch cable. When I look at my triumph 1050, it has none at all in the clutch cable, so it just finds it's own way. And when I think about it, all my big bikes have been like that.

I did this on my last build and it's a revelation. So much lighter than others I've done with same 5 plate and bgm spring set up.

I did think the cable might have hung out hither and thither looking a mess, but it doesn't.


Good call, when you think abaout it its only the gear cables and throttl that need securing on the stem to stop them falling down when changing cable inners.
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Re: SX200, TV200 + LI150 bitsa

Postby dickie » Mon Mar 16, 2020 3:26 pm

coaster wrote:
Good call, when you think abaout it its only the gear cables and throttl that need securing on the stem to stop them falling down when changing cable inners.


Actually, when you think about it, I'm not convinced you need any cable ties at all.

In fact when I build my next one I'm going to try to leave them off completely. A bit of insulating tape for the build phase then take it off when I'm finished. If I need to replace a cable inner, a temporary cable tie or someone to hold the outer in place will suffice...I think.

Although as it's a straight run down the steering tube, you're probably right and it's worthwhile just one tie there.
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