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post #1 of 90 (permalink) Old 09-21-2016 Thread Starter
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Newb with questions about my mini chopper restoration project

Hey. this is my first post and I tried to post it in the mini Mini Chopper up for about $250.00 and it needs plenty of work and I have a laundry list of the things it needs.

1. The Hydraulic Disc brakes do absolutely nothing. The hand lever is loose. I have never used hydraulic disc brakes so im not sure if that's what happens if there is no brake fluid or if it is broken. The same with the rear brake which is applied by a foot lever. That also does absolutely nothing and seems loose like there is no brake fluid. So is that a symptom if there is not fluid or extremely low?

#2. Both of the tubeless tires need to be inflated but they will not inflate. I tried tying a rope around the tire but that didn't work.

3. I tested for spark after I installed a new ignition and it was showing a very strong spark so I tried to start her up and nothing so I figured it was the carb so I opened that up and it was the dirtiest carb me and probably you have ever seen. Everything inside looked very corroded and nasty. It was full of corrosion debris (vert dry and stale, not wet at all) so I attempted to clean it out just to see if I can get it clean enough for the engine to start. The engine did not start and actually did not even turn over when I put the carb back on. It seems the engine is seized now for some reason so I temporarily halted my efforts in the restoration project.

4. My chain is very rusted so im wondering, would a #41 chain work as a good replacement? I prefer it on my motorized bikes but just curious if anyone knows if it will fit the mini chopper.

5. Are there any good videos on how to make a double leg kick stand for the mini chopper?

6. Also, I was trying to determine what the buttons are on the left hand side. One is a on and off switch and just below it is a small black button. (I know the yellow on one on the right hand size is a kill switch)

7. where can I find the same speedometer that is on there? (will get a better picture up soon)

8. I did not have a key for the gas tank so I had to rip that one off. Where can I find a replacement to weld on there?

9. Whats the best way to clean the rust from inside the tank?

10.whats the best way to clean the inside of the engine if there is corrosion inside? (I think its going to look similar to the old carb...hopefully not)

11. I already ordered the new carb replacement and it's the same one except when I measured the old one, the opening where the carb is mounted was approx 15.5mm and the new carb is supposedly 20mm. Will this be an issue where I have to rejet or it not even work because its too big?

12. I will try to post some good pictures and possibly an illustration video for the brakes.

13. Potentially Bad luck

14. Thats all for now. If I can think of more, I will edit or add to it as the list gets smaller.


Last edited by 0to100realquick; 09-21-2016 at 05:26 PM.
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post #2 of 90 (permalink) Old 09-21-2016
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Re: Newb with questions about my mini chopper restoration project

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Originally Posted by 0to100realquick View Post
Hey. this is my first post and I tried to post it in the mini Mini Chopper up for about $250.00 and it needs plenty of work and I have a laundry list of the things it needs.

1. The Hydraulic Disc brakes do absolutely nothing. The hand lever is loose. I have never used hydraulic disc brakes so im not sure if that's what happens if there is no brake fluid or if it is broken. The same with the rear brake which is applied by a foot lever. That also does absolutely nothing and seems loose like there is no brake fluid. So is that a symptom if there is not fluid or extremely low?

#2. Both of the tubeless tires need to be inflated but they will not inflate. I tried tying a rope around the tire but that didn't work.

3. I tested for spark after I installed a new ignition and it was showing a very strong spark so I tried to start her up and nothing so I figured it was the carb so I opened that up and it was the dirtiest carb me and probably you have ever seen. Everything inside looked very corroded and nasty. It was full of corrosion debris (vert dry and stale, not wet at all) so I attempted to clean it out just to see if I can get it clean enough for the engine to start. The engine did not start and actually did not even turn over when I put the carb back on. It seems the engine is seized now for some reason so I temporarily halted my efforts in the restoration project.

4. My chain is very rusted so im wondering, would a #41 chain work as a good replacement? I prefer it on my motorized bikes but just curious if anyone knows if it will fit the mini chopper.

5. Are there any good videos on how to make a double leg kick stand for the mini chopper?

6. Also, I was trying to determine what the buttons are on the left hand side. One is a on and off switch and just below it is a small black button. (I know the yellow on one on the right hand size is a kill switch)

7. where can I find the same speedometer that is on there? (will get a better picture up soon)

8. I did not have a key for the gas tank so I had to rip that one off. Where can I find a replacement to weld on there?

9. Whats the best way to clean the rust from inside the tank?

10.whats the best way to clean the inside of the engine if there is corrosion inside? (I think its going to look similar to the old carb...hopefully not)

11. I already ordered the new carb replacement and it's the same one except when I measured the old one, the opening where the carb is mounted was approx 15.5mm and the new carb is supposedly 20mm. Will this be an issue where I have to rejet or it not even work because its too big?

12. I will try to post some good pictures and possibly an illustration video for the brakes.

13. Potentially Bad luck

14. Thats all for now. If I can think of more, I will edit or add to it as the list gets smaller.

as far as the hydraulic brakes you most likely need to soak the master cylinder in a can of diesel overnight to loosen the plunger pin thenuse a c-clip pliers remove the c-clip holding the plunger in there to remove the plunger to clean all the rust and oxidation out.....you will also need to disassemble the caliper and pop the pistons out to lean the pistons up and oil the seals.....Theres a mod to make them stop with more pressure too....

The front brakes will gravity bleed by itself after a few good pumps with D O T3 brakefluid....The bubbles will rise naturally after half hour of sitting...

To fix the tires I recommend putting tubes......

To clean the rust out of the tank use two stroke fuel and busted safety glass inside then cap it and shake the crap out of it until its rust free.....

To clean the inside of the engine you use plain old diesel fuel.......theres an oil strainer filter tray box in the bottom of the crankcase too

Id take the whole front wheel off and clean out the wheel bearings.......



Welcometo the site

Last edited by CAM2; 09-21-2016 at 07:13 PM.
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post #3 of 90 (permalink) Old 09-23-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

Great info. Are there any videos about popping the pistons out and lean the pistons up and oil the seals? I've got the brakes all disassembled and gonna get some diesel to soak them next. If you can see my picture below, this is how my carb looked but 10x worse. It was almost filled with that kind of gunk.
I put a new carb today and made some gaskets out of napa auto parts gasket material and removed the cylinder but decided to leave it on before it was fully removed since my frame was blocking it from coming off all the way and I would have needed to unmount the whole engine just to get it off and I decided not to after inspecting as much as possible from my viewpoint and not really seeing a need for it. Hopefully, my hunch is correct and there isn't significant rust in it. I drained the oil too. Just gotta fill it up and clean that gas tank and try to start it up again.
I think the reason that I thought the engine would no longer turn over all of a sudden and might have been seized is the way the gears work. I am not use to not having a glutch and still needing to change gears so I think I might have been in the wrong gear while trying to kick start it. When I would attempt to kick start it, the back wheel would want to go which is unusual to me. Can anyone elaborate on this? What gear should I be in when trying to kick start it? zero, correct? Which way on the shifter is zero? All the way back or forward?




Quote:
Originally Posted by CAM2 View Post
as far as the hydraulic brakes you most likely need to soak the master cylinder in a can of diesel overnight to loosen the plunger and pin then use a c-clip pliers remove the c-clip holding the plunger in there to remove the plunger to clean all the rust and oxidation out.....you will also need to disassemble the caliper and pop the pistons out to lean the pistons up and oil the seals.....Theres a mod to make them stop with more pressure too....

The front brakes will gravity bleed by itself after a few good pumps with D O T3 brakefluid....The bubbles will rise naturally after half hour of sitting...

To fix the tires I recommend putting tubes......

To clean the rust out of the tank use two stroke fuel and busted safety glass inside then cap it and shake the crap out of it until its rust free.....

To clean the inside of the engine you use plain old diesel fuel.......there's an oil strainer filter tray box in the bottom of the crankcase too

Id take the whole front wheel off and clean out the wheel bearings.......



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post #4 of 90 (permalink) Old 09-23-2016
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Re: Newb with questions about my mini chopper restoration project

yo waddup cool bikes ya got nice info

Last edited by WizardofKhalifa; 09-23-2016 at 11:56 AM.
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post #5 of 90 (permalink) Old 09-23-2016
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Re: Newb with questions about my mini chopper restoration project

Real quick try giving EPR or CAM2 a pm. You'll prob get a faster response.

IF YA AINT MIXIN GAS YA AINT HAULIN AS*

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post #6 of 90 (permalink) Old 09-24-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

Hey, I will post the results of my restoration so maybe someone else can find it useful. At this point, I have removed both wheels in attempt on bringing them tomorrow to try and inflate or get tubes for them.
I've also submerged both master cylinders into deisel and leaving those for 24 hours in hopes the parts with move freely and etc, so I can fix them.
Ive also put some 2 stoke gas in the gas tank with washers and bolts to try to shake to kick loose some of the big chunks of rust and then rinse with water and then filled the tank with a gallon of vinegar and added some salt. I think I will leave that for atleast 48 hours and then rinse with water and then warm water and baking soda and quickly put some wd-40 to get all the water out before it flash rusts again and then rinse with some 2 stroke gas and then thats done. Hopefully I get that done in the right order I've read about a bad experience with that method

Last edited by 0to100realquick; 09-24-2016 at 01:36 AM.
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post #7 of 90 (permalink) Old 09-24-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

I finished the soaking of the disc brakes in deisel and have a few concerns. The first is the black rubber ring around the piston completely broke. Is that replaceable and will it cause it to no longer function without it?
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post #8 of 90 (permalink) Old 09-24-2016
Re: Newb with questions about my mini chopper restoration project

It's a nice bike, worth getting it running, it just sat to long. The 4 stroke Honda clone engines are not that bad and parts can be found online pretty cheap direct from China most with free shipping, from eBay to AliExpress to Banggood and the .com Seen new front master cylds with lever for 7/8" handle bars for $18 Pays to look around for parts, a PayPal account is free and they have your back. A 15mm carb I got for $9 cost as much as $40 plus at some online stores.

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post #9 of 90 (permalink) Old 09-24-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

Ive got the rear master cylinder working good again but the rear cylinder that holds the brake pads im not too sure or familiar with since the piston barely moved at all and I don't think its normal. All 4 of the pistons on each cylinder seems stuck and if I try to knock them out, they move a tiny bit but not enough to grab and pull them out. Any suggestions?

PS The front master cylinder is the one with the black rubber piece that broke so I guess I might have to replace it unless someone has a solution.
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Re: Newb with questions about my mini chopper restoration project

That rubber piece is it like an O-ring??? If it ins't too expensive Id get a new one and keep the old one for parts. Not whole lot of experience with choppers. PM CAM2.

IF YA AINT MIXIN GAS YA AINT HAULIN AS*

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post #11 of 90 (permalink) Old 09-24-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

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That rubber piece is it like an O-ring??? If it ins't too expensive Id get a new one and keep the old one for parts. Not whole lot of experience with choppers. PM CAM2.
Yeah im gonna have to check that out. Good news though. The tires are good and inflated again. I took them to my old job and they put some air in them somehow. I tried with a rope but those tubeless tires are a pain to try and inflate without high powered air and machines. All for $10. Replaced the rusty chain and this thing is almost ready to start up for the first time in probably years. Maybe I will post a video.
Im wondering about the rear brake cylinders. How do you suggest loosening the pistons if soaking them in deisel over night didn't do it? Id rather try a liquid solution before buying another one

Last edited by 0to100realquick; 09-24-2016 at 06:28 PM.
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Re: Newb with questions about my mini chopper restoration project

Doesn't the wheel caliper split in half and have 2 allen bolts holding it together?? Pistons are probably rusted and the alum casing corroding.

Empty Pockets Racing: The difficult we do, the impossible takes longer.....
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post #13 of 90 (permalink) Old 09-25-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

yes anyone know
1. What the recommended chain is?
2. What the stock chain is?
3. What the preferred spark plug is?

Last edited by 0to100realquick; 09-25-2016 at 02:43 PM.
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Re: Newb with questions about my mini chopper restoration project

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yes anyone know
1. What the recommended chain is?
2. What the stock chain is?
3. What the preferred spark plug is?
The stock chain is #420.............Get one with 127 links plus a masterlink and with a chainbreaker tool or a grinder grind down the pin and punch the pin to size......I use DID brand

The preferred sparkplug is....NGK C7HSA


Last edited by CAM2; 09-25-2016 at 06:35 PM.
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Re: Newb with questions about my mini chopper restoration project

I use my $10 H/F Tools 4 1/2" angle grinder or even 8" bench grinder, grind the pins & down flush and into the side plate, pry one plate off with a screw driver, pin punch the other piece off, clean it up and install new master link.
I spend $5 extra and get the gold chain, #420, much less rusting.

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post #16 of 90 (permalink) Old 09-25-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

Any suggestions how I can purchase something to cap this gas tank for not alot of money ?

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post #17 of 90 (permalink) Old 09-25-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

BTW Thanks for all the replies!
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Re: Newb with questions about my mini chopper restoration project

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Any suggestions how I can purchase something to cap this gas tank for not alot of money ?


Yeah,,,they sell chinese made streetbike gastank caps for like $6.95 with $3 shipping on ebay....
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post #19 of 90 (permalink) Old 09-26-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

Thanks. NVM I found some

Last edited by 0to100realquick; 09-26-2016 at 01:10 AM.
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post #20 of 90 (permalink) Old 09-26-2016 Thread Starter
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Re: Newb with questions about my mini chopper restoration project

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It's a nice bike, worth getting it running, it just sat to long. The 4 stroke Honda clone engines are not that bad and parts can be found online pretty cheap direct from China most with free shipping, from eBay to AliExpress to Banggood and the .com Seen new front master cylds with lever for 7/8" handle bars for $18 Pays to look around for parts, a PayPal account is free and they have your back. A 15mm carb I got for $9 cost as much as $40 plus at some online stores.
The front master cylinder broke while i was trying to knock the piston out and the caliper below it at the wheel pistons wont cooperate so I will likely have to replace both of those as well as both for the rear brake. I think I have fixed the rear master cylinder but anyways, when I search ebay, I am not sure why but I can't decide which I need because my bolt pattern seems to be about 55mm apart and the ones on ebay are either 45 or 65. I cannot find the exact ones either so i am hesitant to buy any replacements.

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