03 patina build

[givergas]

started to tear apart my 03 today. i decided to leave it as is , clean up , replace maintenance items, get in original working order, no painting . seems like its getting harder to find these bikes. my grandson has helped me with the other 3 bikes and he will help with this one. in 5 years he will be 16, times fly's when your having fun , so im leaving this one for him to take apart and do the work to make it like new we will just get it running as it should. a few questions and surprises have come up already. really did not want to see this the mice must of been hungry. i think i need to replace the sprocket, and the oil pump cable ? need to take off whats the secret ? can not get the cable to come out

[olddogs]

Use your thumb or the throttle to rotate the oil pump arm half of its travel and stop the arm. let off the throttle and it will give you enough cable slack to rotate the cable to line up with the slot in the arm. pull the cable straight sideways or use some pliers to wiggle and pull sideways on the brass retainer. its a barrel fitting with a recess for the cable end ball cut in. there is nothing mechanical holding it in.

[thrownchain]

Cable, take a pair of pliers, grip the cable as close to the pump arm as you can, rotate the cable till the cable itself is in line with the slot and pull, you my have to finess it a little, but it should come out. I've seen worse sprockets. And the piston is replaceable, just need to know if it needs a bore or not.

[givergas]

it seemed there was a tiny piece of something in the space where the cable ball recess is, that would not let the ball go back in to the hole so that i could not rotate it enough to pull it out and of course the little piece of what ever it was got lost in the far reaches of the garage when it got pried out. i cut the cable to get it off thanks for the suggestions....albert

[givergas]

couple more surprises, lifted off this gear and found a screw head under it , and something scratched the gear cover up pretty good....albert

[viclioce]

The Model 03 only has std pistons available from Terry, at least that’s all I’ve been able to determine. With that piston being in such bad shape, you may have to go the Nickaseal route & re-bore to Std size. I also know that Terry has Std bore cylinders available. Otherwise it’s bore and change to a Road Toad crank with a 94/95 rod & a 97 piston. Victor

[givergas]

2nd opinion... does this make this side cover to far gone to use...thanks...albert

[givergas]

and how far should you go on taking the oil pump apart.... thanks albert..... ok i will ask a different question about this... has anybody taken a oil pump assembly apart or how do you clean one out of old cruddy oil..?

[givergas]

and how far should you go on taking the oil pump apart.... thanks albert..... ok i will ask a different question about this... has anybody taken a oil pump assembly apart or how do you clean one out of old cruddy oil..?
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[viclioce]

Would like an answer on this question too! I asked if there was a Resonator article on the oil pumps and no one answered. Victor

[givergas]

so after there was no answer to the oil pump question i decided to take the pump apart to see if there was gummed up oil in it and i found that there was none. the oil tank and lines were clogged up so i had to check for piece of mind , not a big deal after all. after cleaning up the cylinder i took a few measurements, the top of the bore , front to back { fore-and-aft } and side to side, were at 2.11 , at the bottom of the spigot , 2.15, so if im thinking right that's just past the thresh hold of a standard piston and would need to go to the next size. put another way i need to bore for the next size piston. any input would be greatly appreciated .....albert

[givergas]

is there a wiring diagram for the 03 wombat ? this one has a lot of wires cut along with being brittle and cracked up....thanks albert

[gearyoliver]

http://hodakapartsidaho.com/index.php/w ... ms-hodaka/

I think you are looking for scan 6.

[givergas]

thank you , appreciate it very much. i tend to get lost trying to find some of the info that's available .....albert

[givergas]

nother question. would the cylinder on a 03 have a steel sleeve ? or is it is it something else . excuse my ignorance....albert

[Bullfrog]

You are on the right track. All of the alloy cylinder small bore Hodakas have "Alumiferric" cylinders - which have a cast iron liner which is in turn cast into a diecast aluminum outer cylinder. Nifty.

[givergas]

Thanks I'm try to figure out my options as this cylinder needs help...Albert

[gearyoliver]

There are a few options available.
The easiest is to purchase a complete new top end from HPI if they are still available. That's the route I took.
Or you can do as Victor suggested and use a combination of bottom end pieces that will allow you to use a model 97 piston.
A third option is the Nicasil coating.

[TheBevman]

If the clutch cover is still able to seal/ retain oil and you can achieve good clutch adjustment then I'd reuse it. I'd just knock down all the sharp points and remove any bits that may dislodge or come off. You can always source another at a later date. I'm using a cover that's chewed a bit too and it's been in service for a few years now without any problems.

Bev

[givergas]

thanks for the picture of the cut out cylinder helped explain it . im looking in to the nicasil coating to see what that involves . and thanks for your opinion of the clutch cover i will take your advise . been real busy last couple of months or so and haven't made much progress , good thing im retired ...albert

[viclioce]

Albert:

Note the nicadil cost may be as much or more than buying a std cylinder from Terry. Terry quoted me $495 for a complete top end, excluding a head. It includes a std NOS cylinder, the piston, rings, wrist pin, top end bearing and circlips. And a Terry had Hodaka Dave check the piston fit with the cylinder.

Terry has an abundance of these and I bought one. If you do the nicasil, it may cost more than the NOS cylinder. And then the nicasil has to be bored to fit a standard piston and you have to buy a new piston assembly anyway.

Just passing the information on. And Terry also has new cases, covers and other Model 03 motor parts in stock as well. So it’s something to think about.

A piston assembly is $169.95. So, if you subtract the cost of the piston set from $495, that leaves a balance of $325.05.

If the nicasil coating and bore costs more than $325, you can come out ahead and no boring needs to be done, and no slowing you down from the waiting for the work to be done and shipping back & forth.

You’ll also pay more for round trip shipping than you will for one way shipping from Terry. So those are the things which made me decide to buy an NOS cylinder from Terry.

And at least yours came apart!!! Victor

[givergas]

thanks victor nice to get your feed back. i like doing business with terry have nothing but good things to say about hodaka-parts and hodaka dave too, both have treated me more than fair in fact i could not of got as far as i have with out there help. im just trying to educate my self on the process i have the time to poke around ...albert

[dirty_rat]

Gasgiver,

I have an old 03 Wombat parts engine if you need some parts (like the clutch side cover). I also have a slightly used 03 Wombat piston, .030 oversize if you could use it. The piston has no rings so you would have to locate some .030 oversize rings (I think Hodaka-Parts.com has the rings). Then you would only have to get your cylinder bored.

Attached are photos of the piston.

[givergas]

so thanks to dirty_rat i now have a .030 slightly used wombat piston, if my thinking's right if i take the piston and rings to the bore shop and give them the specs, max. allowable taper , piston to cycl. clearance, piston to ring end gaps and all the rest by rights thats how the cylinder would be bored to fit the piston and rings ? just trying to learn here, way out of my element .....albert

[viclioce]

That’s correct. I would, however, ask around to your local 2 stroke shops, if your going to do the bore local, as to who the shops use. Go with the one they recommend most often.

I usually just send to Hodaka Dave now. But, there is a guy at one of the local machine shops here who owns & maintains a Honda Elsinore 125. So he has a very good grasp on what to do as long as I provide him specs.