Project KTMito

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

this is carrying on from a thread that started in the workshop section.

So the basic idea of this project was to make the Mito faster. i didnt want to increase the weight while doing so so ive been looking around for a good single to replace the standard engine.
i settled for a KTM LC4 640 4stroke. 55Hp and 45Lbt/Ft of torque (i think). thats almost double the standard Mito power. i saw one on ebay and decided ill have it. the sprocket is on the other side though so i also bought a complete aprilia rs125 front and rear end. and with no measuring the engine went into the frame and swing arm and all fit lovely. now its a case of getting everything to fit and mount and work.

my problems are
-carb hit the top crossmember
-rear shock isnt going to fit without some proper modifications
-general stuff like wiring and pipework
-new exhuast

from the following pictures you will be able to see what im talking about now. im thinking of keeping the rear linkage set up but it means im probably going to have to move both frame crossmembers, which at the same time will give me room for the carb, then fabricate the linkage parts and get it in the right place to mount the sock.

theres an issue with the swing arm as it hits part of the frame as you will see in on of the pictures. bear in mind that the swing arm hasnt been measured up to get it centered but its near enough.

where it hits the frame the lowest part of the frame beneath the pivot is around 33cm from the ground. in the rest of the pictures with my block of wood suspension set up its 44cm off the ground. im not sure how much movement the bike should have at the minute. i think its sitting a bit high but i may be well within my limits to have a good set up depending of if the angle of the swing arm makes much difference. im not an expert of the set up of angle and suspension so i really dont know.

the front end is around 4-5cm higher than the standard Mito so that can come down and will make a bit of difference but as i say, ill need some expert input on that.

ill probably be getting myself a rear shock from Hagon so ill will have all the info i need to get the rear end and linkage mounts in the right place, then its just a case of getting the shock set up.

so anyway thats my main problem but while the top crossmember is moved it'll solve the carb problem too. ill just need to consider the air box, volume, position, intake pipe length etc to make sure i keep that close to standard because im fairly sure changing the intake too much might affect the set up of the carb. but ill look into that.

pictures!!!!

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

few more pictures

as you can see theres a fair amount of difference between the swing arm being high and low but also the angle when its at full 'compression' and hitting the frame. still and steeper angle than standard and it wont go any lower.

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

you can see from the picture looking straight down from above the swing arm linkage mount is out of view. and the position of the crossmembers on the frame arent positioned ideally for it. the Mito shock lays at alot more of a horizontal angle but the aprilia doesnt.

if i moved the bottom crossmember lower and forward closer to the engine then i can mount a linkage between the bottom of the swing arm and the crossmember then move the top one down and back then the shock can mount upright. it sound like it will work. im not sure if moving the top crossmember back will mean it'll need more bracing across the top but i dont really remember seeing any bigger heavier bikes with bracing any further forward than the Mito. so i could well be fine. also the front engine mount will inevitable add some strength. and this frame is pretty meaty anyway

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

heres my crudely drawn idea for the rear linkage. it means possibly adding a mounting point to the frame lower down but it'll look cool and should mean ill be able to use the mount on the swing arm that underneath out the way.

also considering if i can shave a bit of meat off the swing arm where its hitting the frame. i think this one is all cross braced underneath like honeycomb so should still have plenty of strength

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

Great project, but odds on it gets abandoned before it gets finished.

Gaz

ruck bodgers · Trackday Trickster Joined: 31 Oct 2010 Karma :

did a wrong post didnt know how to cancel this one see my username for details
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ruck bodgers · Trackday Trickster Joined: 31 Oct 2010 Karma :

any chance u could make an adapter to fit inbetween the carb and header to shift it past where its making contact out of a chunk of old carbon car header or something or maybe some rubber hosing might lead to some tuning issues afterwards tho so maybe you are better off just sticking to your plan when i raised the rear end on my bike the chain was obstructed by the pivot point i made a chain roller out of a piece of angle and a skateboard wheel worked find but in comparasom to your frame mines anorexic it doesnt look like you have that as an option and i doubt you would want to do that anyway on a race bike aye thats sure is a strong looking frame you have there im not familiar with these bikes or there parts so i cant offer much help im afraid good luck with it tho man Thumbs Up

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Shreddie · Spanner Monkey Joined: 20 Nov 2009 Karma :

Interesting project, I hope you pull it off!

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

ruck bodgers · Trackday Trickster Joined: 31 Oct 2010 Karma :

[/quote]
Is this the longest sentence in history?! Laughing

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haha ye sorry about that officer i dont like to come to a full stop
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i do not think therefore i am . give me a hammer

Damon · World Chat Champion Joined: 24 Aug 2007 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

He reckons it will work... Mr. Green

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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
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Damon · World Chat Champion Joined: 24 Aug 2007 Karma :

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

Got the swing arm. Here's the measurements

Swing overall width 230mm
Swing internal 118mm
Swing length 575-600mm
Rear wheel width 212

258mm
157mm
520-545mm
254mm

As you can see the width is quite wide and the interal width. But I can have the width taken down and make some appropriate sized tube to replace what's been taken off inside. This should put some strength back in but I'm not sure it'll even be needed.

Also its a bit shorter which will affect the handling/stability but I'll wait and see.

Yeah the chain is on the wrong side but if it don't work I'll flip it over and get a new shook mount welded on. Easy.

So yeah this could definitely work. The other option is to go for the previous model which if I remember is a very close match.

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

Sorry that's the original arm measurements on the first bit and the new one underneath

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

Also to stupidgit

Im pretty sure the carb has the be close to the engine. Either way I want to change the least amount possible so of I move the brace all I will change is the airbox and intake pipe. I'm thinking of doing an airbox from carbon fibre. Gonna look into these CF kits.

And the rear shock mount. If I go with this arm it will most likely be linked from swing arm to frame. No linkage.

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

So it's too short, too wide, the chain's on the wrong side, and if you flip it upside down the shock mount's in the wrong place...

It sounds awesome.

Gaz

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

Fair enough, I didn't realise that.

As you were.

Gaz

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

well the main problem was that the swing arm was so high that at full 'compression' when the arm and frame were in contact the bike was still about 5-6inches too high. i did cut a lump out of the arm with the idea of shaping it around the frame so it could drop but i wouldve had to remove most of the metal.

the pictures show the angle. thought i wrote it too....

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

cbr 600 swing arm

the plan is, get it to fit, make sure its strong enough, probably flip it over, cut the mounts and bits off that i dont need and get a new shock mount sorted.

Damon · World Chat Champion Joined: 24 Aug 2007 Karma :

Will be interested to see how this goes Thumbs Up

steven_191 · Nearly there... Joined: 31 May 2009 Karma :

just a few parts off ebay for spares and oil changes.

kickstart that retails at £86
2 sets of oil filters
water pump and gaskets
thermostat and housing
a brand new drive sprocket
and a peg whatsit

not bad for £20 Laughing