My New old dirt bike project. Converting a beat up 2002 Hong Du GY 150 for fun...

[Shanghaifingers]

Well after lusting after a dirtbike to add to my growing China collection of motorcycles I finally had given up when too many difficulties arose getting plate (remember I live in Shanghai....) I gave up, but while on trip to Nanchang China a freind introduced me to this old lady:

She is a 2002 Hong Du GY 150cc, she had 18,000 km and on a second engine(a Jia Ling 150cc) but she was running (barely)
So for a 2,000 RMB I got the bike, plates, insurance and registration... for another 250 rmb I got it shipped to my house in Shanghai from Nanchang. 150 rmb just for the bike to be delivered to the house form the Shanghai depot

Once home the inspection began:






If its not obvious I will tell you she was pretty ratted out, not much left but the frame and engine were in good shape... I love project bikes. So I began to buy what I thought would fit this bike both mechanically and appearance wise... All parts where bought on TAOBAO.com. Mind you Hong Du brand dirt bikes are not rare (not collectable in anyway) except maybe Nanchang but since most older China made dirtbike are simply clones of Japanese bike there is a lot parts that will work for most and the other I just fudged....

New parts included:

wiring harness for JaiLing 150, 40 rmb
plug wire, 10 rmb
spark plug NGK(yeah right) 15rmb each
Piston set( rings, crown, and cylinder)+ full set of gaskets and seals
350 rmb
Valve set from JiaLing 70 rmb
six plate clutch 300 rmb
Control cables 50rmb
exhuast set including can 150 rmb
3.75x21 Kenda front tire 56 rmb
rear brake hydrolic unit 120 rmb
throttle assembly with veiwing window
40 rmb
electric handle bar switches for a Zhong Shen 150cc
30 rmb set of two
horn 10 rmb
front fender 80 rmb
Acerbis hand guard(fake) 60 rmb
Acerbis headlight (fake) 150 rmb
rear fender 35 rmb
LED rear light 15 rmb
LED turnsignals 40 rmb for set of 4
dash light bulbs 15 rmb for 3
reapolster set 60 rmb
Chain tensioner 26 rmb

TOTAL 1722 rmb

So with these part now arriving my garage in Shanghai I set out to begin tearing down the bike:

First thing those stickers have to go, they're all over the bike!


some loose plastic parts and lights



Bike in Box....YEAH!!!!


Old piston rings and cylinder say bye bye


More engine work, includign polishing the vale seats for the new valves..


fresh coat of paint for the frame, a little rewelding and reworking of the rear subframe


Wow that old tired seat has to go...

Oh much better!

So after 3 days of working on the bike, replacing the clutch assembly and the piston set as well as redoing the wiring and hand controls and rebuilding the rear mono shock which at first would rebound slower then molassis on a december morning, the plastic arrives and we begin to see what she will look like in the near future:

nice ass

Looks nice but will they light up anything?( sadly no the lights are brite but are pink in color do to the refelectors, so they don't illuminate anything at all. the LEDs above on the side are nice touch. I wire the LED's for the low beam and the High Beam in the two front main lights...


Again the Fake Acerbis head light, here you can see the LEDs as well as the twin mains(again this is no good for real driving) Nice turn signals though, really cheap and really bright