Honda Chaly ready for paint and building: NEARLY RUNNING

[binge]

Not sure what sort of interest it will gain.
The Chaly is somewhat ready for building now, I've had everything shotblasted, some custom parts made up to run the shortened USD forks.
Got a replacement front hub which runs a disc brake rather than the poxy front drum.
And I've got a replacement rear hub, which offers a bolt on sprocket, over the cush-drive and circlip setup on a stock Chaly.
Dont fancy ripping that out running 18bhp of 155z engine.


https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/529261_10151009148410606_264641306_n.jpg

[Pol Anorl]

Thats pretty awesome look forward to seeing this
____________________
GOOD GAME BODYGUARD: https://i.imgur.com/8WePGgf.jpg
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Jewlio Iglesias: You live in Liverpool - Chances are, the front door has already been kicked off the hinges

[Shaft]

Give it some Boso style..........

https://img855.imageshack.us/img855/3310/chaly.jpg



____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[pepperami]

Sub-frame`s twisted and the chain`s slac....... oh! wait!
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[stevo as b4]

Agreed, this bike could look simply awesome when it's all done. Is the 155cc engine one of these new big bore Chinese versions of the old Honda C90 lump?

I remember that Suzuki and Yamaha made their own equivalent looking bikes to the Honda Chally think they were both 2stroke, i can't remember what they were called though?

I wonder why no-one every bother's with restoring or tuning these similar bikes now? Is it i wonder because you can't get any performance parts for the 2stroke Suzuki and Yamaha engines, like you can for the Honda unit?

[binge]

Yamaha chappy and Suzuki Landie.
Both similar 2stroke bikes. Rare here, but in Cyprus there are thousands of time.
My friend Pavlos owns a shop in Cyprus and sells bore kits, race pipes and tuning parts for them too. Strange that there are hardly boy here in the UK.

[bryvw1973]

looking good
i still havnt started on my chaly but seeing yours has made me want to

[binge]

Got a bit done to the Chaly today, fitted bearings into the hubs, fitted the seat properly, on it's hinge, bolted the fuel tank in, and assembled the forks and bar risers properly.
It's bolted together all sturdy, and feels really nice to sit on. Granted it has no tyres, but the suspension all feels okay. Not a great deal of rebound, but I guess that adds to the riding style of one of these.

Fitted the rear fender, number plate/tail light holder, rear rack etc etc.
The fender needs tweaking, as it's sitting a little squew-iff. Probably down to it been Chinese.

https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/540897_10151012989340606_939674971_n.jpg


Fitted the wheels up properly, with spacers etc.

https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/561302_10151013059590606_1298863786_n.jpg


And a close up of the re-drilled top yoke, and machine work for the headstock, done by Gaz.

https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/555513_10151013064985606_1813553982_n.jpg


Also need to find a caliper to fit this. I know I wont get a direct bolt on unit. But I need something small enough to get on the disc. I didnt realize how small it was gonna be!

https://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/s720x720/282680_10151013067520606_746646889_n.jpg


Will be priming the bike over the next few days, and then applying the colour once I've fully built the bike. I'll dismantle it, paint it with colour and clear coat, then re-assemble.
I dont want to be cutting and modding things on a painted frame that's all.





Ben

[stevo as b4]

Just 2 questions really,
how much does something like this typically cost to build? i.e. im assuming that there is a larget supply of monkey bike style parts available now, and some cheaper chinese parts around too.

If one had a spare KMX125 engine, is there enough room to fit it in there?

[binge]

[binge]

Got another few goodies arriving from OORacing tomorrow.
One of which, is a 28t Talon sprocket for my new bolt-on hub.
Gotta take the hub back off the rim though, and give it back to Gaz, as the edge needs to be machined off, in order for the 28t sprocket to fit. The overall diameter of the sprocket is smaller than the outer edge of the hub, meaning the chain will simply not sit on the sprocket, it'll sit on the hub.


Reason I've gone for such a small sprocket, is because of the engine I'm running in it.
It'd just be lifting the front in all 4 gears if I ran the smallest available 'stock' fitment sprocket, which is a 32t.


Also, I'm replacing the sandwich rack with a nice little grab rail. But the only one I could find was for a DAX. So hopefully it will fit, or can be made to fit.

Will update with pictures tomorrow.




Ben

[binge]

Goodies arrived today. Including my tyres, which I was not expecting.

Tyres are awesome. Nice soft compound, Metzelers! Went with a 3.00 front and 3.50 rear, to try and correct the geometry without adapting the suspension any more.

https://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/581000_10151019197375606_1371509628_n.jpg


I kinda cheated here, and fitted the front tyre, to the rear rim, just to see how much stretch I can get.
Eventually I will buy a mega-wide rear rim (4j) and some sprocket offset plates, then I can shift the rear rim to the front, and run this stretch all the time.
But I dont have the free cash to spunk on the rear rim I want at the moment, as it's tripple figures!

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/556524_10151019847185606_2012595233_n.jpg


Grab bar, chain guard, and sprocket also arrived.
Cant beleive how tiny the sprocket is!

https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/599582_10151019198755606_2030702001_n.jpg

https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/293870_10151019199275606_687195240_n.jpg


And fitted them up. Grab bar needed modding to fit the Chaly, as it's actually for a DAX. But it looks ACE!

https://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/431965_10151019848765606_1383508654_n.jpg

[binge]

Managed to spend the morning working on the Chaly.
Started getting a bit of colour on the frame. Ran out of paint so need to pop into Halfords retail for another couple of tins.
Decided to do the bottom part of the frame black, as it's going to get filthy from the chain etc anyway. Looks smarter black.
I am considering doing all the 'inside' of the frame in white. Not sure yet.

https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/600110_10151058714845606_431359945_n.jpg


Tank has gone black. Was gonna go white, but again, it'll look dirty really quickly.

https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/600050_10151058706380606_646427537_n.jpg


And a quick peek at the wheels. They're not bolted up fully yet as the hubs need more paint.
Rear wheel only atm;

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/524124_10151058709265606_1665973526_n.jpg

https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/302487_10151058711030606_660293309_n.jpg



And some of the ICE i've accumulated over the years, gonna bang it all in the Van when it's done.
Amps are a JL-Audio 1000Wrms amp (Big power!). And a little Alpine 350Wrpm amp for the 6xsh*tes.

https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/314088_10151058711805606_391683289_n.jpg


Ben

[binge]

I'll let the pictures do the talking;

https://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/315423_10151070895960606_2080526295_n.jpg

https://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/313167_10151070899310606_2051046150_n.jpg

[D O G]

Love the headlight eyebrow.

[Aff]

That's hilariously awesome.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Robby]

I quite like that. Would like to build an electric bike based on something like that, lots of space under the seat for a battery pack.

[Tim..]

Cool
____________________
Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[binge]

With the tank removed, there is loads of underseat storage. Tank takes up most of it though.
But obvs on a leccy bike, it wouldnt be there.
Cool idea that! Comfey bikes to sit on, and dead light too.

Got the engine in this evening, and also fitted up a front brake caliper.
It's a dinky little thing, but it will get it through the rollers on the MOT. Anything more powerful and I think I'll run the risk of bending the bars, or the frame.

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/s720x720/255368_10151073162115606_1382851459_n.jpg




Ben

[binge]

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/375757_10151074528010606_449243800_n.jpg

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/s720x720/528755_10151074529130606_1391068969_n.jpg

[N cee thirty]

awesome, vid of it running please
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[binge]

Few bits to do yet before it's ready to start.

I need to sort a carb out for it, and get it fitted properly. The setup there at the moment is a little bodged for my liking.

I also need to do something about a rear brake pedal. The exhaust is right in the way. So a custom modified pedal may be in order.
I might even just run a rear brake line from a scooter right up to the bars, onto a thumb brake lever.

I am also waiting on a stator plate and flywheel, as this thing needs a charging system for the lights.

Soon as it runs, I will upload some videos.
The engine is in quite a good state of tune, and with the sprocket setup it has (17t front, and 28t rear), it should be good for about 70mph.



Ben

[binge]

Been FLAT OUT tonight in the garage. Popped up straight from work. Thought I'd get a lot done, but got majorly held up with the front fender. What a Nightmare to fit to pit bike forks!

Tried everything, even down to drilling and tapping the alloy feet on the fork legs. But they just kept ripping out the threads.
Whatever I did, had to sit flush with the inside of the forks, as this thing has a front disc, so there really is no room what so ever either side of the wheel.
It's already off-set to the right a touch to give more clearance around the caliper.

In the end, I just turned the bike upside down, and drilled right through the fork stanchion. Then tapped an M10 thread into it. Slapped some silicone around a couple of M10 high tensile bolts, and bolted the uprights from the fender, straight into the bottoms of the fork legs.
They arent loosing any oil. So happy days. Will just have to remember than if I ever want to un-bolt it, I need to turn the bike upside down first.

Not the best way around it, but it's not falling off, that's for sure.


Got the bike together 95%. Gotta do some wiring, and get the engine running.
A mate of mine rang me today, I met up with him in Gillingham, and he gave me a genuine Chaly air-box, which comes with the little circular plate that goes in the hole behind the kick start. Well chuffed as they are like rocking horse sh*te.


Anyway, a few pics:

https://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/s720x720/183784_10151102216575606_1295631295_n.jpg


Had to pop a cheeky hole in the frame to get the idle screw in. Cant get the carb in or out with it in place. So gotta fit the carb, then put the idle screw in through the frame.

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/553763_10151102268010606_476901820_n.jpg


Got a full set of XR50 SFB Racing billet engine covers.
Fitted the top cam cover, and the flywheel cover.
The cam sprocket cover is too small for a YX140, and the tappet covers are the screw in type, so no good either.
Had one left over cover, didnt know what it was for, so stuck a couple of holes in the clutch cover, tapped them to M6, and bolted it there.
Looks kinda trick, and covers up the Monstermoto badge.

https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/551583_10151102271410606_2090085847_n.jpg


Pictures dont do it a blind bit of justice, especially with it standing in a dirty garage.
Will get it out in the sun on Suday.

https://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/391195_10151102374770606_1382237326_n.jpg

https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/528145_10151102381475606_97953923_n.jpg

[ThoughtContro...]

[binge]

Its way below the point of travel mate. Its through the ally fork feet anyway.
Forks have been shortened by me anyway, so the bump stops only give them a couple of inches of travel.
Im guessing you've never seen original Chaly forks? They are only sprung, no oil in them.