Honda Chaly CF70

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

Alright guys,

I bought this about a month ago now, for £80. I had to drive to Plymoiuth to get it though! Nearly a 600 mile round trip.

It came with wheels too, they're up in the shed.
It was literally a pile of parts when I bought it, and tonight is the first time I've decided to piece it together to see what I have got to work with.

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/386098_10150513613050606_506045605_8748333_1965503706_n.jpg

The forks and yokes are pit bike ones. CRF50 fitment.
I will probably need to shorten the stanchions to get the ride height right, as when it's on its wheels, the swinger will be sitting level, making the front too high.

I will be running a swinger from a Honda C90, as they are about 4" longer, and have footpegs on them still. Laughing

I've just placed an order for a replacement seat, it's black with Honda printed into the back of it, in white.

Got front and rear mudgaurds, in white. Along with a leg sheld.

Will be running the really tall Chaly/Monkey handle bars too.

Engine wise, to everyones dissapointment, I am going to be running a fully automatic 50cc pit bike engine.
But will be fitting a 110 top end and head on it, to give it a little more go.
It'll still be faster than your average 50cc moped, but it's only a cruiser.
Plus, the petrol tank is dinky, so a fully loaded 160 pit engine wont get me very far due to the fuel consumption. Laughing

Ben

P. · Red Rocket Joined: 14 Feb 2008 Karma :

Very disappointed with the engine choice Laughing

Was expecting a 140/160 and seeing you track it Mr. Green

Subscribed Thumbs Up

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

The problem is, if you want to run an engine with a secondary clutch, such as the 140/150/160 range, you need to hack the frame up to get the clutch actuator arm to clear.
Not something I really fancy doing.
Not only that, Fully auto is the way to go.
It means I can cop my feet up on the frame, and cruise about like they do in Cyprus. Laughing

extermin8tor · L Plate Warrior Joined: 10 Jan 2012 Karma :

Long time lurker of 4 years, first post Smile

I restored one of these almost completely down here in Australia
Feel free to look at my thread for pictures and ideas, etc Smile

https://www.aussiestreetbikes.com/forum/showthread.php?t=12843

https://i.imgur.com/e4mGH.jpg
https://i.imgur.com/03qXo.jpg
https://i.imgur.com/lEXsC.jpg
https://i.imgur.com/IGOh4.jpg

bryvw1973 · Two Stroke Sniffer Joined: 16 Jun 2009 Karma :

ill be following this as ive just bought a chaly project im yet to start.
do the 110 top ends fit straight on the little auto engines?as i dont want to alter my frame either
also how straight forward was the fork swap? im loving the look of usd forks

cheers
bry

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

grahamd1 · Trackday Trickster Joined: 04 Aug 2011 Karma :

This is my Chaly (also rebuilding, as and when I find the parts)

https://www.bikechatforums.com/viewtopic.php?t=226879&highlight=chaly
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

Charlie · World Chat Champion Joined: 27 May 2007 Karma :

Chives also made an attempt at restoring one:

https://www.bikechatforums.com/viewtopic.php?t=184370&postdays=0&postorder=asc&start=0
____________________
Past: Honda x8rs, Honda City fly, Honda Hornet 250, Honda VFR750, Yamaha xt600e.
Current: Honda CBR929RR & Yamaha XT660Z Tenere

ms51ves3 · Super Spammer Joined: 07 Jun 2007 Karma :

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

Loving the input here, didnt realise there were so many Chalys hiding out there.

Not really got anything to update.
My pal Gaz has just taken a few of the bits to his workshop to sandblast for me.
He'll be doing the frame next week.

I've just bought a few engines, and hopefully I can graft them together to make the high output semi-auto hybrid I want. Very Happy

I also managed to pick up a set of original handlebars and risers for £12 delivered. Cool

I've noticed from the pictures that they have the lever perches built into the bars... Strange.
Will have to take a look at them when they arrive. I may well grind the perches off, and fit regular levers and perches, providing they are standard 7/8 bars.

Ben

ms51ves3 · Super Spammer Joined: 07 Jun 2007 Karma :

Just out of interest, Binge, what forks are fitted to yours and would they take the standard wheel? I imagine not but it's worth asking.

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

They are a set of SDG mini-pit forks from a Demon X pit bike. With yokes from something else, cant remember what it was.
I've had to mess around with the stem bolt, as the Chaly has like a 7" long headstock, and any pit bike has a 5.5" headstock (Sometimes 6.25").

Will be shortening the stanchions in the forks to lower the front.
The front wheel should go straight on, but you'd need to make a little bracket from the caliper mount to the drum brake, to act as a torque arm.

Or, OORacing sell a front disc conversion for the Chaly. It's just the hub, and has a 3 bolt face on the hub to run a disc.
It's what I will be doing.

They also sell a rear disc hub, with a solid mount sprocket conversion, to get rid of the horrible cush drive. Laughing

colin1 · Captain Safety Joined: 17 Feb 2005 Karma :

i'm liking the aussies emoticon Smile

https://www.aussiestreetbikes.com/forum/images/smilies/ride.gif
____________________
colin1 is officially faster than god

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

Managed to get a Honda VIN plate for the Chaly, as it doesnt have one, nor does it have any substantial frame numbers as the frame's been painted so many times.
Need to find somewhere who can engrave / stamp it professionally, so it doesnt look like a ringer! Laughing

Nice tin pressed plate for the old girl too.

https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403625_10150538574505606_506045605_8826241_1669935890_n.jpg

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

Okay, decided to bin the semi auto / fully auto idea, and just go balls out with a massive motor.

Here it is:

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/396083_10150541000550606_506045605_8831870_1460627732_n.jpg

Re-shimmed the gearbox to get a tighter gear engagement in second as the bigger engines are prone for jumping in 2nd and 3rd.

https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/407197_10150540999440606_506045605_8831866_129052037_n.jpg

Here it is:

https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/408191_10150540938285606_506045605_8831768_107752680_n.jpg

It's a Zongshen 155 engine. Latest and best one on the market for pit bikes.
Will have to modify / cut the frame to get it in, but who cares! The Chaly isnt a restoration project anyway.

Will still look fairly stock as far as the bike goes. Cant wait to start dicking on Ped boys with it! Laughing

Them 155 engines produce about 15hp.
With a few mods and some head work, can get them up to 20hp~.

Ben

P. · Red Rocket Joined: 14 Feb 2008 Karma :

Man points have been restored Thumbs Up

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

Right, having a look at the engine tonight, and mocked it up in the frame.

Looks like I need to do a few things:

Remove some of the cooling fins from the cylinder head and barrel of the engine. As they dont fit up inside the frame.
It's only on the right hand side though, above the spark plug.
I'm running a extra large oil cooler though, so removing the fins shouldnt be a problem.

I need to mount the clutch cable perch on the frame somehow, for the cable to clamp into. As it doesnt fit under the frame.

I will also need to either modify the actuator arm for the clutch, or cut the frame. Not sure how I'll cut the frame though as it's right beside where the engine mount is. Confused

Time to experiment and research.

Ben

garth · World Chat Champion Joined: 15 Dec 2004 Karma :

If you decide you want to mod an auto, I might have one.
____________________
You ain't a has been if you never was

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

Well the Zonga 155 is in! Cool

No cutting engine fins at all.
Just a small cut had to be made to the inside of the frame on the secondary skin steel. Had to take out a 1" square section to clear the Cam Chain tensioner.

And I've had to bend the clutch actuator arm up a tad higher, along with space the bracket out for the clutch cable using longer bolts.

Had to make a few cuts to the leg sheld too. Needs to be neatend up still.

Handlebars have been heavily modified. I've cut all the built in throttle away. Removed the built in levers, and pulled all the wiring out of them as it had all broken up.
I've fitted regular pit bike levers and throttle to the bars too.

I wont be running any switch gear as such. Just a simple 2 button unit, for horn, and high beam on/off.
Lights will be on all the time. I will probably pass them through a switch under the seat or something incase I ever want them off.
And an ignition will be fitted somewhere at the bottom of the bars. Maybe in the side of the frame near the seat like on the road legal pit bikes.

Seat, mudgards etc all arrived. Very happy with them. Cool

https://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/408063_10150550524105606_506045605_8862080_1979595264_n.jpg

https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/397056_10150550525315606_506045605_8862088_162190887_n.jpg

https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403028_10150550492905606_506045605_8861984_623306475_n.jpg

garth · World Chat Champion Joined: 15 Dec 2004 Karma :

Sweet.

Chinese / American seat?

PS What's the orange stuff in the coke bottle? Swarfega?
____________________
You ain't a has been if you never was

UnspeedySam · World Chat Champion Joined: 25 Nov 2009 Karma :

binge · Emo Kiddy Joined: 02 Jul 2004 Karma :

AL- · World Chat Champion Joined: 17 Mar 2005 Karma :

looking forward to seeing this progress Cool

garth · World Chat Champion Joined: 15 Dec 2004 Karma :

Gotta get a pimp exhaust and shocks like my cub. Cool

____________________
You ain't a has been if you never was

P. · Red Rocket Joined: 14 Feb 2008 Karma :

Gotta have a go on that Laughing