Valley Vintage Minibikes

Well, the first thing to do is to try and get it running!  It has spark, fuel and the air filter is clean.  Compression is present on my pinky when put in the spark plug hole, but I don’t have a 10mm adapter to screw a compression tester in.  A quick check of the valve clearance finds no clearance!  Adjusting intake and exhaust valves to .002 and .003” respectively and voila!  It fired right up. Having a new knee made it tricky, but a test ride was in order.  You’ll note the one leg doesn’t quite bend into place!  It ran awesome and certainly is faster than any other 50cc bike I’d ridden.  Hmm, now I needed to consult the internet to see if anyone had ever stuffed a Honda type engine in a traditional minibike frame.  I come across a couple sites, but one in particular, Red Beard’s Garage, showed a Honda engine going into a Coleman bike. Mike and I watched that episode and then out come the measuring tape...

A friend, Mike and I were touring down to Sterling Ontario area to pick up some Ski doo Elan parts last Spring and we were quite successful as the fella had exactly what I was looking for and was very knowledgeable.  Armed with tons of early snowmobile parts, Mike and I noticed a small bike under a  trailer.  I asked the owner what the story was on it and he said a guy had asked him to get it running as it had quit.  He didn’t have any luck starting it, so he just set it under the trailer and the bike owner didn’t want it back.  It was a 50cc pitbike with 10” wheels, the size that was originally on the Fox minibike.  We negotiated a deal and loaded it into our vehicle!  Here’s Mike on the l’il 50.  It was fairly complete, but not running, I was unsure if I could use any more than the wheels.

Well, I’ve finally decided that after seeing how difficult it is to find original Fox minibike parts, that I would find a donor bike and “update” this one.  I picked this up at the Eganville Vintage Snowmobile Show and Swap Meet last year, attracted to its front and rear suspension design.  A member on oldminibikes.com identified the bike for me.  When I looked into the Fox minibike ads, I saw they had a disc brake and several models.  I loved the chrome gas tank that came on them originally, but couldn’t locate one. Follow along to see how this bike was reborn!

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This is an episode from an off road show I watch called, Dirt Every Day.  Hosts Fred Williams and Dave Chappelle take a couple bikes across a mountain, strapped with “essential” gear to make the trip.  Here are some pics from the show and the link to watch the whole episode on YouTube.  It’s a hilarious adventure, not to be missed! Link to: Dirt Every Day’s Mini Bike Trip

Well, this is the final installment of this bike build.  One other thing to mention is that when fitting a 125 to a CT or and small bike chassis, the foot pegs need an hour or more of “adjustment” with some heat.  This is because the 125 is wider than the 50 or 70 engine.  The bolt pattern for fastening the foot pegs is the same though.  It just takes a bit of work to get them to clear the engine and sit level.  Finishing touches were to install the headlamp and bezel, engine oil and adjust everything.  John V. bought the bike and kept it for a couple years.  Pete bought it from him and rides it regularly.  Pics include John riding it at the sand pit near Norway Bay, being parked up at Bell’s Lake after a day of riding and it loaded with the other 1978 CT70 I fixed up.  It is a fast bike, wheelies with ease and is very reliable.

Now the fun begins!  This was the second 125 engine I had installed in a CT70.  They open a lot of doors as they have big power, CDI ignition and a 12 volt charging system, meaning lights are considerably brighter even if you use a voltage drop and reuse the 6 volt bulbs. Again as Josh says, just two bolts and the engine’s in!  This engine requires throttle cable and twist grip changes.  Also, as it’s a 4 speed manual, a clutch lever was added.  The colourful decals were applied, following the location recorded before stripping the original paint.  A gas tank was cleaned, new lines, shut off valve and gas cap were all installed.  The rear brake pedal and rod, return spring and small parts were cleaned, repainted and installed.  As the bike was going to only be used off road, the awkward turn signal arms were left off. As a bigger engine works nicely with a free flowing exhaust, an order was placed with Motor City Mini Trails for one of their S...

The wheel bearings have been replaced and packed.  Rear sprocket tooth count was considered and changed as the added power of the 125cc engine could produce enough low end hill climbing power and yet have better than stock top speed.  Fork seals were replaced and lower fork tubes were sanded and resprayed silver along with the wheels.  This silver paint is the Duplicolor Wheel Coating, available at CTC.  Clear coat added on top protects that finish.  The rear fender and a new seat was added after the wiring harness and ignition coil were installed.  An original pair of shocks were disassembled, cleaned and the springs were repainted black.  All aluminum parts that aren’t painted such as the brake plates and the steering triple clamp were polished to a high gloss using Autosol polish, also available at CTC.

Here the frame has been sanded and painted parts treated to a black lacquer paint job.  Pressure was a bit high in the gun, but wet sanding will remove any “orange peel” look. Just a note on the paint stripper.  Although there is no warning about an explosion hazard, that’s what happened to me when I brought the can home in the back of the truck.  The sun had shone on it while I loaded other things in the back of the truck.  When I started to unload, I noticed the can was swollen.  I reached to relieve the pressure by loosening the cap.  It exploded with such force, my eyes were forced inward and I couldn’t see for about 10 minutes.  Being paint stripper, I was worried it was on both me and the truck and I couldn’t see anything!  I was alone in the backyard at the house and blindly walked towards the house where I knew the garden hose was.  I turned it on and ran water over my face for about 10 minutes.  As my sight began to return, I r...

I had bought a collection of bike parts, including about 4 frames.  Two were the 1978 black models and there seemed to be enough parts in the boxes that came with the frames to redo the two black ones.  I didn’t have a good enough engine to rebuild, so a swap to a Lifan 125 cc four speed with a clutch was planned.  The process began with disassembly and stripping the paint off after measuring and recording decal placement.

Well, this is it for coverage on this CT restoration.  Some finishing notes though...  When I went to put the chain on, I couldn’t get the wheel to look straight when I aligned the axle locators with the swing arm.  It turned out the swing arm was bent and I didn’t notice that when I bought it.  It’s hard to tell that it is bent if the wheel isn’t on the bike.  Anyways, I sourced another, sanded and painted it and changed them out.  This bike being an early model, has the plastic gas tank, so rust was not an issue with it.  A new cap and we were all set.  I finished it in 2015 and have used it every year since.  It always starts and runs sweet.  Last year, I brought it into the garage to set the points and valves.  Purring like a kitten.  Keith at PhatMX swapped me the correct exhaust system for it for an NOS one I had for another year.  That was the finishing touch!  Hope you enjoyed the build; I did! ...

At this stage, the seat, handlebars and switches, throttle and brake cables also are installed.  The wiring is connected to the ignition switch, the gas tank, lines and battery and box are also installed.  The major wiring junction is within the headlamp housing.  It, too had to be sprayed to match.

So here is the original engine from my Topaz Orange 1973 CT70.  It has only about 1800 miles on it and was removed to make room for a fresh 108cc Honda motor from PhatMX.  As Josh says, two bolts and it’s in!  Also here, the decal installation begins.  Careful measurements and looking online at original bikes ensured they were put on in the correct place.

This is the fun part where every step makes such a noticeable difference.  The taillight mount, new steering head bearings, hubs, wheel bearings, brakes and wheels and tires were all installed.  Now being a roller, the rest of the refurbished or new parts could be positioned and adjusted.