It's time - Honda Chaly resurrection

[binge]

Okay, so today, it was 30/31 deg C in sunny Sittingbourne, I start another (Better) job on Monday, so decided I will begin my long weekend, by doing something constructive.

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/q71/s720x720/600818_10151739779095606_1238209612_n.jpg

Plus, the new job means I will have my weekends back, so can spend the back end of this year heading up north more often to see family, go to bike rallies, and generally have a bit of fun before I grow up and buy another house.

So I started out, by having a clear out in my garage yesterday, to make room for my tools as they are coming home from work. No more fitting for a profession. YAY!

Should be enough room. Ground anchor is all fitted too.

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/q80/s720x720/1098286_10151738214830606_1751842370_n.jpg


Looking a little sorry for it's self, I dragged the Chaly out from under it's cover, and propped it up on an old tool chest to humiliate it for blowing up on me earlier on this year!

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/q77/s720x720/993649_10151740739870606_1479283126_n.jpg


Within about 45 mins, it was stripped back to a chicken bone, and jet-washed off, ready for either a re-spray, or touching up.

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn1/q75/s720x720/60510_10151740813740606_1054762502_n.jpg


And I decided to mount my new tyres (Smaller tyres), onto my new rims (Wider rims). It's got a bit of stretch, doesn't show up too well in the picture, but I am still tempted to go a little wider at the rear (rim that is, not tyre). But do need to have a balance between form and function.

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/q84/s720x720/1098536_10151740869140606_2051908675_n.jpg



The new engine of choice, is going to be a Lifan 125cc Semi-Automatic, which comes with the big valve head.
My options with this engine are then endless. I can go down the routs of decking and turning down a YX140 barrel, and fitting my Lifan 150 head I currently have. Or I could just accept it for what it is, and run it as a 125cc.
Either way, the option will be there.

Semi-Auto means I can get rid of the foot brake, tuck my exhaust up higher, and then lower the whole bike another inch too.

Will be running the rear brake on the left hand bar, and I will also be doing away with the foot shifter, and fabbing up a suicide shifter I think.


More updates to come, Gaz currently has the forks and yokes, he is machining a set of mini dirt-bike forks down to fit into a set of Honda DAX yokes. Custom FTW!




Ben
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[bren_9311]

Has potential
____________________
My opinion is neither copyrighted nor trademarked. If you like, I'll trade for one of yours.
Currently bikeless.
Ps4- bren_9311

[binge]

This is kind of what it looked like before, minus a few bits like the air-box, and indies.

https://i902.photobucket.com/albums/ac227/pitbikeben/2012-08-18193502.jpg
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[Sako]

First dibs if you ever sell it!..it looks the tits

[binge]

Aha cheers. It's going to be infinitely better this time around. For a start, it isn't going to have dirty great big pit bike forks bolted to the front. Instead, it will have a set of spring only (Just like standard), mini mx forks on it. They are the same spec, size, length, and diameter, as original Chaly forks, but they have a mounting lug for a caliper, instead of a wafty brake drum on the front wheel.

The smaller engine will also mean I wont need to mess around bodging oil coolers on, and modding the leg shield to clear the head it.
It will all tuck away nicely and look stock.
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[stevo as b4]

I've ridden a C90, but know naff all about the Chinq powerhouse's that are based on the same design. But the C90 is what 8bhp, so a 125cc engine with an alloy barrel and big valve head should be I dunno 11-12bhp? With a 4speed semi auto box that ought to be plenty for the lol's in a bike the size of a Chaly IMO.

I'd still have loved to see one with a Suzuki/Yamaha 2stroke lump in there and a fat spannie hanging off the side!

Loving the big Chunky USD's by the way!

[_Iain_]

I realy did like this little thing when it was first posted up on here.

Will be watching with interest!
____________________
Please be aware that the above post may be full of complete nonsense.
Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340

[P.]

Free at weekends...

BCF BBQ is on a weekend...

You know what to do

[MarkJ]

Congrats on the new job, what are you doing now?

Looking forward to this thread, you did a good job with it last time

[Pol Anorl]

Didnt realise how close you live to me, i need to see this in person!
____________________
GOOD GAME BODYGUARD: https://i.imgur.com/8WePGgf.jpg
20:30:37 Pyro.: I don't sort of like men, I take every advantage to choke on dick.
Jewlio Iglesias: You live in Liverpool - Chances are, the front door has already been kicked off the hinges

[binge]

Regarding the power of the Chaly. The previous engine (Not the one in the picture of it built up, that was a 140cc). But the engine fitted when I was using it, was a Lifan 150 Daytona style engine. It was running a high lift cam, and a Mikuni VM26 carb. Would run on the rollers at around 16/17bhp when fully set up. The thing was capable of 70mph+. Fucking scary mind you!

New engine should be perfect, although I'm considering a Honda C90 engine now. For pure reliability purposes. We shall see what crops up.

Once done, it will be at the Oakdene on a Weds evening again, like it was last year.


Paddy, PM me details of said BBQ.
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[binge]

Block of flats is home.

Red box is for sale. Not sure on what it's worth.


https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/q72/s720x720/1005337_10151742981415606_1077729549_n.jpg
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[binge]

Got my forks back off Gaz today.
Both legs have been turned down by about .2mm to get them inside the DAX widened yokes.
Top clamp is a chrome Honda flat pressed steel type, both fork legs have been drilled through the top to 11.5mm ready for some Riv-Nuts fitting to bolt them through the top yoke.

They will run on one of the mini hydraulic Mini-Moto calipers I think, but need to double check on the mouting. They do look very IS fitment, but smaller, with M6 holes? Maybe a Hope caliper will go on?


https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash3/q82/s720x720/535742_10151746940420606_838565223_n.jpg
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[_Iain_]

Binge, if it's of any use to you i have a mini moto with hydraulic brakes i'm in the process of rebuilding the engine on. If you needed to borrow the brakes off it to try em on & work out spacers etc then give us a shout
____________________
Please be aware that the above post may be full of complete nonsense.
Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340

[binge]

Nice offer Iain, but I've bitten the bullet and bought a Hope M4 caliper.


Got to the garage today and assembled the front end. I've not painted it yet because the bottom yoke will still need to move a small amount depending on where the bearings need to sit in the headstock etc. I am going to be painting the legs and bottom yoke together as they are such a snug fit, it will mark the paint if I paint them separate then put them together.

Everything fits nice, only concern is there is a bit of 'twist' in the fork legs, I think the riv-nuts I've fitted into the tops of the fork legs cant offer enough torque, and the knock on effect is a bit of play in the legs.

I may look into the anodized fork leg braces you can get for the DAX etc. They should fit as I am using DAX yokes.


Look a little better in size than the old pit bike things though;

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/q81/s720x720/969610_10151751389350606_1361733019_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/q80/s720x720/971002_10151751389545606_549552486_n.jpg


Caliper mount does look very 'IS' fitment, but I sure as hell am going to need that bigger disc for my Hope M4 caliper.

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/q77/s720x720/76038_10151751389125606_1817443756_n.jpg
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[binge]

Headstock bearings arrived from OORacing. Bit gutted as the lower bearing's inner-race has cracked as I've pushed it down onto the stem. Must have been fractured from factory as there is no way an inner bearing race should break, they're mentally hard metal!

And the hope caliper is a little smaller than I thought it was going to be.


I eyed the caliper up, it didnt fit as well as I thought it was going to, and going for a bigger disc would not of worked either, as the angle was wrong.

Luckily the bracket on the fork leg had enough material to re-drill, and get the caliper sitting perfect.

The next thing I had to mod, was the banjo bolt on the caliper. Being MTB, it runs M6 banjos. I need a minimum of M8 in order to run off a pit bike/monkey bike master and line.
M10 was out of the question, as there wasnt enough meat on the caliper. But M8 was fine. Checked my current set up, and the caliper was M8 anyway.

Drilled and re-tapped the caliper, fitted up the Chaly master and braided line (As it has a brake light switch), bled it through, and jobs a good-un.

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/q77/s720x720/7166_10151759154975606_723089920_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/q82/s720x720/935896_10151759155880606_1564635493_n.jpg


Since the photos I have painted the fork legs blue, but not re-assembled them yet as the paint is still drying. I will do that in the week.

There is a bit of forward/backwards 'throw' in the legs, between the stanchions, and the upper legs. Just cheap forks which are un-oiled. Cant say there is any more play in these than there was in my old CRF50 though, so hopefully it wont be a problem when on the road. Even contemplating fitting a small valve 110cc now, rather than a 125.
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[binge]

I think a 110 small-valve is going to be my weapon of choice, as I am pretty sure all the Honda CRF50 covers fit onto them. Also means I will be able to run an OEM peg bar and pegs. They dont seem to clear the cases on the bigger valve 125cc engines etc.

Tonight, I fitted the forks. They look a little more at home with a splash of colour.
Still doesnt look right as it's not got a fender or headlight, but they are the next steps.

Lowered the back end too, although now it looks a little bit too low compared to the front. Until all trim etc is fitted though, I wont know.


https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/999995_10151765183395606_10084644_n.jpg
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[stevo as b4]

Looking good!
How's that badass van going BTW? Have you put some monster TD engine in it yet?

[binge]

Nope, Van is still a N/A Derv. Fuel pump has started surging though, so think it'll be due some TLC soon. I've just bought a 6n2 polo though, and possibly bought a Mk4 Golf Cabriolet.
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[garth]

Be interested to see how you go about moving the brake to the bars. Are you going to use a coil spring like the front of a C90?

I've done it on my C90 endurance racer with a cable and bracket, with double springs to help it back - it's still not very effective.

Ignore all the above if you're converting to a disc.

125 Lifans can be converted to semi auto but the clutches are a weak point. Most of these still come with the fat clutch case, even if bought in semi guise. The SS50 style (for a manual lump) or C90 (for semi) are a swap.

[BravoCharlie]

watching this

[binge]

Okay, maybe not the exciting post you guys want to see. But I've sourced myself an engine for the Chaly.

I've opted for the Stomp ACE50 motor. 3 speed semi-auto, based VERY close to the Honda CRF50 engine.
Tuning potential is an E22 head, and a 72cc bore kit. This will make it up to the original Honda Chaly engine capacity, with a little extra power, but will keep it looking stock.


https://i1134.photobucket.com/albums/m620/skipp110/20130827_133602_zpsa3f0a9f3.jpg
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[stevo as b4]

Interesting!
So how would the Stomp/CRF50 engine with the 72cc conversion compare to a std C90 engine?

I thought that the C90 lump looks pretty similar to the original Chaly engine as well?

I think Honda did a 110cc version of the C90 unit with an alloy cylinder barrel for a 3wheeler ATV as well?

[binge]

With the E22 head, and a decent carb, it will be as fast as a C90 I guess.
I'm more interested in up-hill torque than anything. With these new forks, and tiny brakes, I don't want to be doing much past 30mph anyway.
BUT I don't want to be practically walking it up hills, like most 50cc mopeds now days.


C90 engines etc are all a good bet. But they're all old, shagged, and tired.
The Stomp engine I've bought is quite new. And parts are readily available from most pit bike suppliers, for a nice cheap price.
And being a low CC, it wont be a time bomb like the 160cc engines.
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[garth]

Don't know why you haven't done a 110cc 4 speed Lifan.

Cheap, extra gear, a little more grunt and would look standard with a C90 clutch case.