79 Puch Free Spirit Project

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re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Wed Jan 08, 2014 3:20 am

The shoes and brake drum turned out well. I ended up using some 600 grit wet/dry sandpaper with brake cleaner to get the rust and other junk out. Then it got polished with some emery compound.
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The ball bearings got re-packed with new grease.
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The new crank arms had to have their pin holes enlarged. Treats swears that these work with 9.5mm pins. My pins are 9.44mm and are still too big. Some time with the Dremmel took care of that though.
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There where a couple of spacers I wasn't sure about, but fortunately, my old manual had a diagram. Made reassembly much easier.
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Mike

1979 Puch Free Spirit
1987 Honda Rebel
2014 Ural M70
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re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Sat Jan 11, 2014 6:42 am

Finally got the wheel parts back together. It turns out, I'm missing some ball bearings from the freewheel.
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And also the spacer. Fortunately, while I decide what to do about that, I have a spare freewheel that I cleaned up not too long ago.

I got the pedal crank, chains, tensioner, brakes, and all that stuff back together with no extra parts. My manual was a little vague about how to align the back tire. With the proper chain tension on the engine side, I'm supposed to adjust the position of the axle on the pedal side until the engine drive chain looks straight between the two sprockets. I decided to be a little more thorough. For every turn I gave the left alignment nut, I gave an equal turn on the right. Starting with the axle all the way forward on the swing arm.

It took about ten-ish turns to get the right chain tension, with a little fine tuning at the end. But I think I got it pretty strait.
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The condition of all the sprockets was really quite good. This bike only has around 1,200 miles on it, and I can still see most of the grains and ridges left my the machining process.

Well, its all put back together. I'm ready to test out that new carb jet as soon as the weather clears up a bit.
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Mike

1979 Puch Free Spirit
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re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Thu Jan 16, 2014 3:35 am

I got the moped out for a test drive today.
http://youtu.be/pIilsQtIHxU

Its still very stubborn to start.
Stumbles a bit when the throttle gets opened suddenly.
Still not much low end power.
The midrange is still good.
Full throttle is much better with the #74 jet.
Its pulling itself up hills way better than it used to.

I'm going to try a larger atomizer tube. My current one is either a 2.12mm or 2.17mm. I forget which. I recently acquired a 2.20mm I want to try. I've also just bought a 2.24mm atomizer on eBay. I think those are the biggest ones made, and they are getting hard to find!

The rear brake is so much better! Its not grabbing or squealing, but has much better stopping power than it used to. The front brake is next!

I'm going to have to look at circuit #3. I keep popping my 5A fuses. It didn't used to do that until I added the volt meter. Normally I'd hook it directly to the battery... but I don't have one of those.
Mike

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re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Thu Jan 23, 2014 5:03 am

I replaced my 2.12 atomizer with a 2.20:
http://www.youtube.com/watch?v=_JSYyAB6u8Q

I found it a little easier to start.
The choke can be removed sooner.
Way less stumble when the throttle is suddenly opened.
Maybe a little more low end power.

I think I'm closing in on my carb tuning, but I'm still going to try out a 2.24mm atomizer, and larger jet sizes. I might put my needle up another notch or two also. I'm getting a small collection of Bing parts:
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re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Thu Jan 30, 2014 2:21 am

Grandpa donated his bearing collection to the moped project.
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I've already used some to finish rebuilding the original freewheel that came on my bike.
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This one is in better shape than the older spare one I did a while back, so that's good.

Its nice to have an assortment of these things. I still have the front wheel and the forks to clean up. They both have loose bearings too. I don't think there will be any that are bad or missing, but you never know...
Mike

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re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Sun Feb 16, 2014 7:26 am

More parts and tools means its time to fix up the crank/gearbox part of my engine.
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The first part will be port matching. I have a K-star performance top-end kit, and I've decided to re-shape the case ports to match. To get the shape, I put a little oil on the cylinder jug and put the new gasket on top of that. Doing that left dry spots that could be removed.
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The newly shaped was used to mark where the extra material is to be removed.
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Just to be safe, I checked several times to make sure I wasn't removing too much.
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I also made some shims to make sure the cylinder jug didn't move around much on the engine studs.
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Finishing with that, the two halves of the case got bolted back together so I could match up the seems. Since I happen to also be rebuilding a stock e50, I was able to take a comparison picture.
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Rather than trying to grind strait back, I made a curve from the new edges and blended it with the original shapes about half way back. With a little sand paper, The new ports almost look like they are supposed to be that way.
Mike

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Re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Sun Feb 01, 2015 12:00 am

I've been offline for a while, but I've made some progress.

Both engine cases have been cleaned up and are ready to paint.
One is mine with the modified ports, and the other is my son's, unmodified.
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Here's my engine parts painted. I used VHT engine paint. Cured in the oven.
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The engine now has new everything. Except the big transmission gear and shaft. It was in perfect shape.
All sealed together with Honda Bond.
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I swapped the old flat-head engine bolts for ones that take the hex driver.
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Here is the adapter plate installed for the new generator upgrade. No more woodruff key.
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New coils. Electronic Ignition, and 12v 8A for the electrical system.
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Setting the timing:
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Reused the old rubber plug:
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Most of the engine complete. I need to change the shims so the new clutch will fit the new shaft properly.
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Mike

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Re: 79 Puch Free Spirit Project

Postby mountainmoped » Sun Feb 01, 2015 11:03 am

Very nice job.
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Re: 79 Puch Free Spirit Project

Postby mopedlar » Sun Feb 01, 2015 12:26 pm

Looks beautiful, but couldn't the paint cause heat not to dissipate properly?
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Re: 79 Puch Free Spirit Project

Postby John » Sun Feb 01, 2015 6:04 pm

That VHT engine paint covers with a nice thin coat. Their brake calliper paint also is similar. Heat doesn't seem to be an issue. Drying time is very fast as it flashes off quickly.
John

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Re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Mon Feb 02, 2015 1:06 am

Thanks for the comments folks!

I'll be keeping an eye on the engine temperature. In the mean time, here are some random things I've gotten done lately.

Expanded my jet and atomizer collection.
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Spent a long time cleaning up the old kickstand. I've also added truck bed liner to the feet.
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Cleaned out the fuel valve. Again.
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Cleaned and coated the inside of two gas tanks.
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Sent several parts to the powder coaters.
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Mike

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Re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Wed Feb 04, 2015 1:14 am

Got an assortment of sizes, of large and small shims for the new clutch.
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I increased the shim thickness below the bell by 3mm. This raised the whole thing up just enough so the pressure plate can disengage.
To keep everything tight, I decreased the shim thickness above the bell by 3mm.
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The new clutch is that 3-shoe "Superclutch" sold at 77mopeds.
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I also replaced the old pressure plate with a more recently designed one.
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The cover screws have been replaced with ones that take hex driver bits. These can be torqued to specs so much easier!
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So there's another milestone for the project: the engine rebuild is complete. (Unless it doesn't work...)
Mike

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Re: 79 Puch Free Spirit Project

Postby churioz » Wed Feb 04, 2015 10:53 pm

Damn nice job! You're an inspiration!
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Re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Fri Feb 06, 2015 8:27 pm

Thanks! I spend a lot of time just sitting and thinking, or searching for You Tube videos from other moped mechanics who have more experience than I do.

Well, my parts came back from the powder coaters. The results, in my opinion, are fantastic! I have most of what I need now to build two mopeds.
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The red one will be a separate project though.

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Also, for keeping an eye on engine temp, I got a CHT gauge.
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Mike

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Re: 79 Puch Free Spirit Project

Postby RebelRider.Mike » Sun Feb 15, 2015 1:14 pm

The powder coaters did a fancy pattern for me on the gas tank.
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This is where the project starts looking like its name. :)

The rims now have their new tubes, tires, and sidewalls.
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A lot of the roads around here are gravel, or have collections of wet fir needles. So I went with a set of slightly larger Shinko tires.
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The back wheel did not fit quite right at first. I finally figured out that the aftermarket swingarm for Maxis don't fit the Free Spirit.
But The one for Magnums do. Here is a comparison. The original Free Spirit is in the middle. Left is for Maxi, Right is for Magnum.
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With the Magnum swingarm, everything fits perfect. Its about an 1 1/2" longer than the Maxi. Makes all the difference.
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Mike

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