Cheeky Chaly Rebuild

[binge]

It'll all work out okay in the end.
Let me finish.
____________________
- 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.]

Watching with interest.

Just started on a road legal pit, also going for a 70 engine. Need to come on a minibike rideout - theres few people locally that have them now!

[Ste]

Haterz gonna hate!!

[Doovy]

[stevo as b4]

Silly thought of the day, but could a kids mini bike like a Yamaha PW80 be made road legal?

I've seen enough of them being ridden along local ring roads at midnight by hooded teens anyway!

[waffles]

Aww I was hoping you would go for a dark purple with silver flake in it

A pink Chaly looks interesting....
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[binge]

I've got friends who have put CR80s on the road, and similar.
Few ways of going around it. The most common (and easiest way) used to be registering it as an Enduro bike.
Few simple hurdles to jump, like minimum seat height, and ground clearance, a few forms, and you've got yourself a reg cert.

Other way is by means of MSVA, which were very difficult and long winded, but then you end up with a proper registration, rather than something registered as an enduro on a non-age related plate (Q plate).

It's been done though, plenty of times.

Chaly is all papered up, which is why I bought it some 4 years ago now.


Not loads to update just yet. A few more odds and sods turned up in the post. I'm just waiting on some new headstock bearings, and I can get it built up to a rolling chassis again.
____________________
- 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 -

[ms51ves3]

Mint!

[Ste]

Your build threads are generally excellent.

[UncleFester]

Are you planning on sneaking a way to humping Jordan / Barbie?

Joking aside, it will certainly be unique
____________________
Module 1 and 2 passed - October 2014. Happy owner of a 2017 Z1000SX, ex owner of a YBR125 / CB500 / VFR800.

[binge]

This'll certainly be the most quirky build I've done.
In all honesty, it'll probably not get ridden too much/far.
Mostly because it's going to be lowered more than in the first picture. And secondly, I really could do with another big bike anyway.
Chaly will end up being a bit of a trailer queen I think.


In relation to the colour.

I'm tempted t add a second colour, and theme it a little bit.

Touch of yellow:

https://media.tumblr.com/0e8fa20f14dd89f8230a92b4f06d011f/tumblr_inline_mtmayxAUkk1rwnjjz.jpg


Touch of purple:

https://c1.staticflickr.com/5/4135/4823190846_3c2efed8b1.jpg


Or just another shade of pink:

https://www.disneyclips.com/imagesnewb6/imageslwrakr01/febr226.gif
____________________
- 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 -

[UncleFester]

You could call it the 'PP Special' I quite like the idea of that

Penelope Pitstop or Pink Panther ... your choice
____________________
Module 1 and 2 passed - October 2014. Happy owner of a 2017 Z1000SX, ex owner of a YBR125 / CB500 / VFR800.

[binge]

Or even Pink PowerRanger.

https://s-media-cache-ak0.pinimg.com/736x/e1/44/21/e1442148e6bae1e1c776a74daaa01566.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]

Fitted the rear hub up to the rear wheel/tyre.
37t sprocket fitted, but I have a 28t and a 30t ready to fit, if I decide to upgrade to a bigger engine again.

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xlp1/v/t1.0-0/p526x296/10384931_166093173741716_4230671183667605328_n.jpg?oh=392a52583c46a04ba23ac247d35e941f&oe=56B97B31

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xal1/v/t1.0-9/12039332_166094913741542_9116661692820728944_n.jpg?oh=c1eddba1098a4a174659be400d17041a&oe=56BCAD62
____________________
- 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]

Little bit more progress today.
Built up both wheels and put a new innertube in the rear.
I'm a little confused with the front wheel, and wont know if it's right until I try to fit it into the forks.
The rims are offset, and you can mount the rim either way on the hub. I cant for the life of me remember which way around it goes on.
The tyres are rotational, but the type that go one way if mounted on the front, and the other way if mounted on the rear. So I am hoping they were fitted the right way around the start with, and I've just gone with that.
Worst case scenario is I will need to whip the tyres off, and fit them on the other way around, Then flip the rims on the hubs.

I also ordered some high tensile socket cap bolts, and had a go at fitting them as suggested.
Nice chrome dome capped nuts on the back of them. Looks pretty smart.

Front wheel without disc adapter fitted.
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/12038138_167027243648309_1893408029155617856_n.jpg?oh=c9d578b252e99f06b86f1fde156de14b&oe=5686DD4D

Front wheel with the disc adapter my Granddad made.
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/12042962_167027173648316_1602786636455881067_n.jpg?oh=debb316138463e6f45e817335deebbca&oe=56889506

And front wheel with the 203mm Hope disc fitted up.
https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/12049558_167027146981652_7326553858759540083_n.jpg?oh=32e45ed7dbd49526ec1a82b420eb4036&oe=568AE4D0

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xla1/v/t1.0-9/1896920_167027130314987_6466989724524724383_n.jpg?oh=c882c0c3bb500d70493abc5d2f127e67&oe=56C62546

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/12189576_167027083648325_8691831628942917221_n.jpg?oh=9e0e491c287f78edb2efd32127992869&oe=56C87DF9

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpt1/v/t1.0-9/12036665_167027110314989_1362593374641672645_n.jpg?oh=212b9aa398c9365b2aea5fc7800480e4&oe=56C8152A
____________________
- 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]

[binge]

Chuffed with my purchase today.
Needed some new engine casing bolts as the old ones were broken and/or missing.
Honda wanted silly money for a set (8 bolts, £19.99!)
Found a fasteners on ebay, managed to buy all the right bolts, enough times to kit about 5 engines, for £6.40.
____________________
- 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'm still loving this bike and the re-build even in Pink.

I also really like the front brake set up with that trick cool machined 4pot caliper and nice mounting bracket too! And I like the way it's going to be ridiculously overbraked for a 70cc engine, with what 7-9bhp?

I'd like to put a small 4pot caliper on the front of my KMX, but it's got a 230mm disc, and other than a trials bike caliper I don't think much else would fit? I might look at Hope and see how much they are, as it's a cool caliper indeed!

[binge]

It's probably not even 5bhp.

Had a mess around tonight. Nothing really in the way of any pictures.
Started looking at making up this rear hand brake mech.

Think this is what I will need to knock up in order to have a brake cable perch which bolts to the frame, but allows the cable to sit in line with the rear lever on the drum.

The will need to make some sort of clamping mech for the cable. Probably use a solderless gokart nipple or similar.
____________________
- 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]

Oh, and the brakes are going to get better as I've just bought a new floating front disc, and some sinitered pads, as I'm fed up of the old ones squealing like a pig every time I pull the lever.
____________________
- 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]

And it's made:

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xtp1/v/t1.0-9/12187866_171453956538971_1085988726341416297_n.jpg?oh=d2e6c2ae513e17f7a2ed73dd183fdd63&oe=56B2BDCA
____________________
- 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 -

[stinkwheel]

You get neat cable stops for bicycles that clamp onto frame tubes, seatposts and headstocks.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Iain.]

[binge]

Interested in these cable stops.

Looking at my bottom yoke, I can probably fab a plate up which bolts across the two holes used for the horn bracket.
And then bolt an ally stub upwards, centrally in the yoke, so it hits the bump stops around the bottom of the headstock.
I just need something, because my leg shield is getting damaged, and it's an original Honda one.


Got a bit more done today.
Fitted up the pipe work:
Could probably do with a little skid / bash plate welding to the header pipe though, as it'll have worn through before long. haha

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/12189888_172002663150767_1372773053009410367_n.jpg?oh=fb16ea7f68c62a5543683df14877790c&oe=56B46317

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xat1/v/t1.0-9/12189825_172002749817425_8884285583077590498_n.jpg?oh=570549d1a1efe57b690b4c51d9a22ed8&oe=56AC6E5F


Hand brake perch and cable all fitted up.
I would like to do something with the cable where I've connected it to the original brake rod.
At the moment, I've cut off the threaded end on the brake rod (m6 threaded bar basically), and used a tiny u-clamp to attach the steel inner brake cable to it.
Some sort of adapter would be nice. I tried using the brass insert from an electrical lego-block, but it wasn't strong enough to hold the cable.

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xtp1/v/t1.0-9/11210393_172002706484096_8775089827281174801_n.jpg?oh=5686b8ab0b8fccb89ed606ba71415f54&oe=56C43E56

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/12208852_172002733150760_3897534247708272003_n.jpg?oh=f10f270365b8bc5d63432e8688d4e74e&oe=56B3EC93


New front brake rotor arrived. Didn't fit the adapter for the old disc though.

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xlf1/v/t1.0-9/12193356_172066349811065_2522515585192074755_n.jpg?oh=364dd4a6aa8007220baac3ff06ca6392&oe=56C12501


But Busa Pete to the rescue again. Made child's play of modifying it for me.

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/12105924_172096936474673_550930377788455516_n.jpg?oh=628d6c15abaaafbfbcbec46bb1548dfd&oe=56ACB912


https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xtp1/v/t1.0-9/12189755_172133263137707_5588030738018952693_n.jpg?oh=16e5fe55bd10612b6b23b884622bc31d&oe=56B3B78D

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xlf1/v/t1.0-9/12063646_172133196471047_2482391936407083725_n.jpg?oh=730b4341fa4fdd899a1648f1dadffc51&oe=56B0779C

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xta1/v/t1.0-9/12122760_172133226471044_8393772975150046736_n.jpg?oh=c351580564d881c60cf6525179a8758f&oe=56BE0F5B


Loads of bits arrived today.
New bar ends and grips, A new chain, a new and un-cut carb cover as my new carb is low enough to fit under a standard cover.
Battery cover for under the seat, and some new frame badges.

I'm just waiting on some headlight brackets and then I can get it built up and start working on a new loom.
____________________
- 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 -

[Pete.]

It fitted then? Christ, that was lucky....
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good