PUCH 250 SGS

Restoring a barn-fresh 1966 Sears Allstate

Spring in my step

With spring just around the corner, and the annual pilgrimage to the CVMG Paris Rally, I have been working on getting my Puch 250 SGS suspension overhauled. The rubber  seals have long gone brittle and what little oil remains is thick and gooey.

IMG_0003The forks I discovered are bent, not surprising considering the condition of the front fender, the dented fork covers and handlebar into the tank. One is bent more than the other – I will seek out a hydraulic shop to see if they can straighten them out.

I took the shocks and forks apart to assess the condition of the components in case more than consumables are needed. Luckily,  seems all is in order, just dirty, gooey and decomposing or brittle rubber bits. One fork seal was brittle enough to almost cut my hand, the other was fairly supple.

20150218_093335_cThe rear brake lever (part no. 175.4011.2) I ordered from Motor West arrived today, or should I say the envelope arrived. It appears the envelope tore open and the lever fell out.

Packing tape was invented for a reason, Matt. *Update: Matt has graciously offered to send me another at no charge. That’s class.

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Puch parts – and progress

I bit the bullet and ordered a new (low) Magura handle bar, and a complete headlight assembly as my chrome rim is shot and the reflector is completely fried (see photos). Ed (from the forum) and I grouped up on an RBO order to save on shipping.The headlight is euro spec, with a different build and a separate pilot bulb. Luckily I found I have a euro spec bulb, I think it was thrown-in at a swap meet purchase. I love the Puch logo on the lens.

I took the opportunity to dig into cleaning up the handle bar clamp as it is not available from RBO (I didn’t bother to check other vendors). The clamp was so corroded it was like a flaky bar, I took off a lot of material to get it down to where it was reasonable to try and polish, it came up rather ok, the before photo doesn’t show the actual corrosion eating into the alloy. The levers polished up nicely too, the lever and the clamp seem to be different alloys as they patina differently. I’m not going too crazy polishing, just getting them back to shiny so it looks good with those sparkly new bars.
Its nice to actually do some work on the Puch 250, it has been a long time sitting in the garage, waiting patiently.

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Parts in the mail, hole in the fender.

I received som parts form Bill in the US. I was especially looking for the left sidecover. It looks good.

I picked up a sealed 6v 12aH battery and thought I’d see what happens. To my surprise and delight it sparks and the lights work! I posted a video in the forum. http://puch.nortonfastback.com/forum/viewtopic.php?f=3&t=4

PUCH_250_sidecover_parts

While cleaning the gunk/goo off the rear brake arm, I noticed that there was something behind the licence plate. Now we’ve stared at this bike for untold hours – poked it and noodled with it (not actually doing any real work on it) and never noticed.

puch_platesI took off the top bolt and could see there was a plate below.

PUCH_250_1969 A nice Michigan plate. Much better looking and in better condition than the yellow 1970 plate.

PUCH_250_1969_fenderNow I have a hole in the fender. I think this a a result of the aluminum plate rubbing on the steel. At least it is in a hidden location so I don’t have to kill myself fixing the hole.

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