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H100S2 Project......20bhp tune up!

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cb1rocket
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PostPosted: 13:56 - 31 Aug 2012    Post subject: H100S2 Project......20bhp tune up! Reply with quote

Hello all, I thought I would post up and share my progress with the rebuild of my H100S2 which I have owned for over 10 years (jeez has it been that long?!)

My dad bought this for me after some little scrote nicked my scooter, and at the same time was my first introduction to a manual gears bike.

So pictures below as its stands after 45k plus miles of abuse and neglect by me, oooops! I have another that is very well looked after by me (call me a mature and loving owner! Very Happy ) and in the meantime the knowledge I have gained from maintaining the 1st H100S has helped me look after the weak points of the bike.

First photo as it (She?) stands and further photos on stripping it down.
The engine was already in my brother's H100 as well, and his engine gearbox bearing exploded on the mainshaft from a camping trip to Wales. I then put the engine from this project bike into his bike and then 500 miles later the crankcase main bearings went. However during that time, his bike got nicked and they ragged it around the field Evil or Very Mad So in the meantime I rebuilt my brothers old bike and rebuilt his original engine, and mine came back out for a rebuild. I didn't want to refit the engine if I was going to do this project up, hence no engine in there at present! (Save time stripping the engine out!)


http://cdn.bikechatforums.com/files/15082012672.jpg

http://cdn.bikechatforums.com/files/15082012669.jpg

http://cdn.bikechatforums.com/files/15082012681.jpg

http://cdn.bikechatforums.com/files/15082012683.jpg


I will edit and add more photos later


Last edited by cb1rocket on 09:00 - 06 Feb 2013; edited 1 time in total
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UnspeedySam
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PostPosted: 14:10 - 31 Aug 2012    Post subject: Reply with quote

Nice project Smile So your family have had 3 H100s in all?

Is that a trusty Lidl socket set I see? I really see no reason to replace mine.
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cb1rocket
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PostPosted: 14:24 - 31 Aug 2012    Post subject: Reply with quote

yes its a lidl socket set, make it 5 H100s hehe
2 of them on the road, 1 off the road, 1 project (this one) and 1 H100SD being broken up!
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UnspeedySam
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PostPosted: 14:28 - 31 Aug 2012    Post subject: Reply with quote

cb1rocket wrote:
yes its a lidl socket set, make it 5 H100s hehe
2 of them on the road, 1 off the road, 1 project (this one) and 1 H100SD being broken up!


Wow...so it's safe to say you think they're decent bikes... Razz
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cb1rocket
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PostPosted: 22:18 - 31 Aug 2012    Post subject: Reply with quote

getting there, tasty road muck! Under the crap is actually quite clean and unbroken paint, suppose road muck is good to a point!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon01.jpg

bastard swingarm bolt doesn't want to budge

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon21.jpg

hmmmm

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon20.jpg


crap Sad, its in a bad state and the threads are a bit mashed up from hammering it out, new bolt and nut ordered

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon19.jpg


As you can tell below, its getting new bushes anyway! Out you come you little swine! Butane gas torch and lots of swearing!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon18.jpg

little F***** stil doesn't want to budge, so some improvised press
http://i212.photobucket.com/albums/cc108/CB1Rocket/icon16.jpg

yeah!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon15.jpg
http://i212.photobucket.com/albums/cc108/CB1Rocket/icon14.jpg

Ok, on to the 2nd one, thread on the studding of presser strips! D'oh!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon13.jpg

Lots of hacksawing and cold chisel forcing it out. This took 2 hours! I almost gave up!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon12.jpg
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cb1rocket
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PostPosted: 22:25 - 31 Aug 2012    Post subject: Reply with quote

Frame finally stripped, ready for powder coating

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon11.jpg

Centre stand, sorry no before photo here but basically i just cut out the previous crap welding I did when the stand folded under the bike!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon10.jpg

And lots of welding later and sanding down, all ready and cleaned up for powder coating

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon09.jpg
http://i212.photobucket.com/albums/cc108/CB1Rocket/icon08.jpg
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Tim..
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PostPosted: 22:46 - 31 Aug 2012    Post subject: Reply with quote

Well they didn't want to come out did they!
You got an engine for it?
I once looked at putting a Honda 650 lump into one of these, was just too big to wedge in without major modification though. Effort I wasn't willing to put in at the time.
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cb1rocket
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PostPosted: 23:11 - 31 Aug 2012    Post subject: Reply with quote

yes still has the original engine, it was once in my brother's H100 while i was rebuilding his, then the project engine went bang! That has also been rebuilt and is ready to go back in
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cb1rocket
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PostPosted: 23:39 - 31 Aug 2012    Post subject: Reply with quote

right, next is rear wheel, photo basically shows it has had it, spokes missing and the rim is rusted to buggery, still solid mind.

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon01-1.jpg

New rims from david silver spares!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon02-1.jpg

New stainless spokes from CWC, pattern made to match the old ones. These were but cheaper than the genuine honda spokes that just rust!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon01-2.jpg

started cleaning up the hub after cutting away from the old rim

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon07.jpg

followed by 'I got bored of cleaning' so I tried lacing em up to the old rim to see how it goes together bearing in mind this is my attempt at wheel building, did do a lot of studying months before!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon05.jpg

Followed by removing the bloody bushes again, this time the hub, not too bad I first thought but required alot of effort levering them out and chiselling the outer collar of the bushes. Also had to burn the rubber out on some of them!

[http://i212.photobucket.com/albums/cc108/CB1Rocket/icon06.jpg
http://i212.photobucket.com/albums/cc108/CB1Rocket/icon04.jpg

Little piss takers - goodbye!

http://i212.photobucket.com/albums/cc108/CB1Rocket/icon03.jpg
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cb1rocket
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PostPosted: 23:49 - 15 Sep 2012    Post subject: Reply with quote

Not much to update so far on this, still waiting from the powder coaters for my frame. Apparently my frame isn't a priority for them!

Then city link loose a box of parts that I ordered on ebay, with a signature that doesn't match the name! They never even turned up but have it signed for?! Really gutted as thats 40 quid lost! If anyone has any advice please say! Crying or Very sad

so some photos now, new parts arrived for the swingarm Very Happy

http://i212.photobucket.com/albums/cc108/CB1Rocket/SDC11642.jpg

Followed by starting to clean the hubs and back plates

http://i212.photobucket.com/albums/cc108/CB1Rocket/SDC11649.jpg

Painting them

http://i212.photobucket.com/albums/cc108/CB1Rocket/SDC11650.jpg
http://i212.photobucket.com/albums/cc108/CB1Rocket/SDC11651.jpg

Starting to rebuild the wheels
http://i212.photobucket.com/albums/cc108/CB1Rocket/SDC11652.jpg
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GrumpyGuts
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PostPosted: 00:05 - 16 Sep 2012    Post subject: Reply with quote

Keep it up! I'm seriously considering buying a non runner in the new year and doing it up!
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AnPhonEh
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PostPosted: 13:32 - 16 Sep 2012    Post subject: Reply with quote

GrumpyGuts wrote:
Keep it up! I'm seriously considering buying a non runner in the new year and doing it up!


I'd like to do the same. The amount of work you guys put into this stuff is amazing. Wish I had the space to do the same.
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SQL
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PostPosted: 16:54 - 16 Sep 2012    Post subject: Reply with quote

Chain looks slack
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cb1rocket
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PostPosted: 16:35 - 28 Oct 2012    Post subject: Reply with quote

Ok some more updates. Wheels built but not yet trued. Frame powdercoated after 4 weeks! My frame wasn't a priory..sigh! Getting the bearings in the swingarm and start rebuild the frame.

Pics below

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121025_194105.jpg
http://i212.photobucket.com/albums/cc108/CB1Rocket/20121025_181212.jpg
http://i212.photobucket.com/albums/cc108/CB1Rocket/20121022_132508.jpg
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Zen Dog
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PostPosted: 17:39 - 28 Oct 2012    Post subject: Reply with quote

Loving this project. Thumbs Up

Zen Dog
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stevo as b4
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PostPosted: 21:16 - 28 Oct 2012    Post subject: Reply with quote

It's coming on a right treat so far!

Nice to see someone having a go a wheelbuilding too!

What are your plans for the engine? re-build/tune?

I've been told that the MTX80 has the same bottom end as the H100 engine, and that you can get 110/115cc big bore kits for them with improved porting etc.

having said all that my mate had what looked like a pretty std H100 back in the day, and it would do 65mph+ all day and wheelied unbelievably well off the throttle in 1st/2nd gear.

Was almost more fun than a TZR125 with the power valve locked open, and much better for mono wheel action too!

It would be nice to see a H100 with a few tweaks maybe around 14-15bhp and a front disc brake and maybe some alloy wheels and upgraded forks and shocks. I wonder if an NS125 front end would fit ok?
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cb1rocket
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PostPosted: 23:56 - 28 Oct 2012    Post subject: Reply with quote

stevo as b4 wrote:
It's coming on a right treat so far!

Nice to see someone having a go a wheelbuilding too!

What are your plans for the engine? re-build/tune?

I've been told that the MTX80 has the same bottom end as the H100 engine, and that you can get 110/115cc big bore kits for them with improved porting etc.

having said all that my mate had what looked like a pretty std H100 back in the day, and it would do 65mph+ all day and wheelied unbelievably well off the throttle in 1st/2nd gear.

Was almost more fun than a TZR125 with the power valve locked open, and much better for mono wheel action too!

It would be nice to see a H100 with a few tweaks maybe around 14-15bhp and a front disc brake and maybe some alloy wheels and upgraded forks and shocks. I wonder if an NS125 front end would fit ok?


I have looked into tuning this bike. Already have a Micron exhaust for it, tried it and it was not much better than standard. The most annoyining thing on this bike is the restricted reed intake. Word got round that an MTX125 reed block would fit but it doesn't Sad

Engine is already rebuilt Smile
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cb1rocket
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PostPosted: 19:44 - 08 Dec 2012    Post subject: Reply with quote

Some more progress after over a month doing nothing and getting other crap plus work out of the way!

Well I decided to get the forks polished awhile back and clean up and repaint the yokes and brackets etc. Would of been nice if I could of powder coated these at the time but rang out of time when getting the frame shot and powdered.

Need to rebuild the forks but the priority is to get it going as a rolling chassis now! And the get the engine back in and start her up! Then do the final prepping and painting after. The frame is all ready so nothing to stop me there putting things back together.

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121208_144717.jpg

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121208_151110.jpg

Progress on de rusting the bits.

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121208_151630.jpg

Painting the bits

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121208_162924.jpg

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121208_162931.jpg
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ocatoro
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PostPosted: 23:19 - 08 Dec 2012    Post subject: Reply with quote

awesome Very Happy Thumbs Up
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.Chris.
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PostPosted: 00:00 - 09 Dec 2012    Post subject: Reply with quote

cb1rocket wrote:
My frame wasn't a priory..sigh!


Might have a bit of trouble powder coating one of those Razz.
Sorry, couldn't resist.

How easy was it to rebuild the wheels? I wouldn't mind doing the same on my GN400 (with a rear rim the next size up) but would be worried about cocking it up.
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MarkJ
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PostPosted: 01:13 - 09 Dec 2012    Post subject: Reply with quote

Cool project Thumbs Up

Did you get anything out of City Link? One of their drivers ran over a parcel we'd given him to send. It fell off a post he'd balanced it off when loading the van up, fell off under the tyre. He drove over it then tried to sling it in the back. Receptionist saw this and got it back off him. We had it recorded on CCTV and everything and I think all City Link would give us was 10. It was a 300 clocking in system.
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cb1rocket
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PostPosted: 13:27 - 09 Dec 2012    Post subject: Reply with quote

@ chris. The wheel building where you laced the wheels together is fairly straight forward but the hard bit which I haven't yet done is truing them. Though I must say I had a lot of fun doing the wheels.

@ markj. City link was a right royal pain in the arse. Manage to get a refund off Paypal despite the seller complying with all the rules. He was uncooperate when I tried to explain what happened. Probably thought I was pulling a fast one, but then I can understand if I was selling something and someone pulled that trick on me. City link did admit something was fishy but never went any further than that. So at least I got my money back but I'm still fucked off that the parts I wanted are so rocking horse shit, it's almost impossible to find the spares. Indicator stems and a seat pan in good nick. I'll be lucky. The SD model that i have broken up uses a different type of indicator stem. No wonder the SD model was shit, the parts on that particular model was done on the cheap!

I have now run out of aldi's cheap hammerite paint. Does anyone know of any place that does the same for 3 quid? I have used it on my brother's bike to good effect. Fuck paying 11 quid for hammerite! Evil or Very Mad
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cb1rocket
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PostPosted: 19:20 - 09 Dec 2012    Post subject: Reply with quote

Bloody double post

Last edited by cb1rocket on 00:12 - 10 Dec 2012; edited 1 time in total
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dangerousdave
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PostPosted: 20:29 - 09 Dec 2012    Post subject: Reply with quote

great work Thumbs Up
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cb1rocket
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PostPosted: 22:04 - 03 Jan 2013    Post subject: Reply with quote

So I got some more progress done by truing the wheels which took about 3 hours for both wheels, so quite chuffed (and yes dished correctly so it is sitting central on the hub).

Did all the truing on the bike frame as I didn't have a truing stand and just using a pen as a pointer and my vernier caliper as a rough guide to getting the wheels trued.

And some new parts fitted, shame I can only find one left hand headlight bracket!

Getting there I think...!

Packing new grease and new ball bearings

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121227_001408.jpg

Yokes back on

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121230_170303.jpg

only one new NOS....sigh plus NOS mudguard!

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121230_170019.jpg
http://i212.photobucket.com/albums/cc108/CB1Rocket/20121230_170049.jpg

wheel truing

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121230_201847.jpg

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121230_232427.jpg

not forgetting to lockwire the trunion (sp?) to prevent it falling out and being lost!

http://i212.photobucket.com/albums/cc108/CB1Rocket/20121230_202142.jpg
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