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Cheeky Chaly Rebuild

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binge
Emo Kiddy



Joined: 03 Jul 2004
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PostPosted: 14:53 - 14 Oct 2015    Post subject: Cheeky Chaly Rebuild Reply with quote

Well, it's been a year. Chaly has been stuck in the back of my garage over that period and un-used. Down to quite a few things, one being the new house, and another being work commitments.

But I'm fed up of looking at it, with crap piled up on the seat, looking sorry for it's self.
So I pulled it out into the garden, and did this:

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/1557488_161128157571551_999543961548400655_n.jpg?oh=e717f38a14193bee9466e13721f155a5&oe=56CB5A6C


I'm just finishing off a sandwich, then I am going to drive down to the powder coating firm, and decide a colour on my journey.
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Doovy
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PostPosted: 15:33 - 14 Oct 2015    Post subject: Reply with quote

First!

Looking forward to see where this goes. I've always liked the look of it, and the bike work you do Thumbs Up
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mrbox
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PostPosted: 17:59 - 14 Oct 2015    Post subject: Reply with quote

look forward to seeing this Thumbs Up
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binge
Emo Kiddy



Joined: 03 Jul 2004
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PostPosted: 19:10 - 14 Oct 2015    Post subject: Reply with quote

So this is what it used to look like:

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xlp1/v/t1.0-9/12105760_161139680903732_7815487428247615524_n.jpg?oh=bf97609d4402f268d2ae668ee291e389&oe=568865B1


It had an incurable running problem. I'm pretty sure it was down to the fact the carb was too big. No amount of jetting would fix it.
The engine is marked up as a 49cc, but I was told by Stomp (As the engine is out of a Stomp ACE50), that it's actually a 70cc.
So bought a carb suitable for a 70cc engine. But it bogs if you rev it too quickly, so have to wind the throttle on real slow.

Rather than keep ball arsing around with it, I've bought a PZ19 carb, as apposed to the 22mm carb currently fitted. Hopefully that should cure the issue.
I tried a stock Chaly carb, but they're so old and fucked now, that it never ran too well on that either.

I also need some plastic welding done to the leg shield. It's an original Honda one, but where it's been pushed from pillar to post around the garage, it's cracked in 2 places. The pieces have not broken completely away, but they've getting that way, so i'd like it welding up asap.
Any recommendations in the South-east?

Wiring loom is/was pure shit. So I've chopped it all out, going to make my own. Will get up to a breakers yard and cut a big section of loom from a car.

It's got an alarm fitted, but I'm going to do away with that too, because it was no good with the tiny battery fitted.

The other situation I have is the rear brake lever.
It hits the floor when cornering to the right.
So I will be converting to a handlebar lever, using a clutch lever, and custom cable.

Style:

I've chosen my colour. I will reveal all when I get the frame back.

I'm going lower, slower, and a little more tricked out. No point trying to keep it stock looking as it's hardly original Honda anyway.
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- 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 -
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stevo as b4
World Chat Champion



Joined: 17 Jul 2003
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PostPosted: 20:13 - 14 Oct 2015    Post subject: Reply with quote

Excellent to hear about and see this bike again! I always loved it and think you did a brilliant job on it first time, being a sort of performance retro machine.

Is it a semi auto engine like the 3speed Honda C50-90 series or one of the 4speed manual motors instead?
Either way it's a cool bike, and can't wait to see what you do with it! Thumbs Up

BTW what's been happening with the fully pimped out Tranny lately?
And the Rotax 122 ultimate pit bike?
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binge
Emo Kiddy



Joined: 03 Jul 2004
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PostPosted: 21:12 - 14 Oct 2015    Post subject: Reply with quote

First time it was on the road, with the oil filled pit bike forks fitted, it was powered by a Lifan (Daytona style) 150cc, 4 speed manual engine.
Used to fly past 125cc 2t scooters. Laughing
But it would only use 1/2 tank of fuel, and then cut out, as the carb sat quite high (Higher than the fuel tap).

Second time (with the small springer forks fitted), it was fitted with, and still has a 4 speed semi-auto engine out of a Stomp ACE50. Supposedly 70cc, but I have my suspicions it's actually 50cc.


Transit has gone to the scrap yard. I sold everything off first, and scrapped the shell.
Split up with no Ex (for the third time), and moved out so the van was just in the way.

Rotax 123 pit bike is still here. It's next to the box of Chaly bits in the garage. Could really do with carrying on with that, but I've kinda forgotten how far I got. Once Chaly is done, I will probably carry on with the Aprilia.
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- 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 -
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binge
Emo Kiddy



Joined: 03 Jul 2004
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PostPosted: 23:14 - 14 Oct 2015    Post subject: Reply with quote

I am also going to need some new bolts to built the wheels up.
The old ones I had worked, but was not right.

I'd like some M8 bolts, around 20mm long. But they need to have a 14mm hex head on them, rather than 13mm.
This is because they located in the cut outs in the hubs, and are held still so you can drive the nut on to the back of the wheel.
13mm bolts just spin in the hole. I held the last ones by putting a flat blade screw driver into the gap around the bolt head, and the hole.

But this of course, is not right... And once my wheels are freshly powder coated in their new colour, I'd rather not chip them. Razz
____________________
- 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 -
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DrDonnyBrago
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PostPosted: 23:56 - 14 Oct 2015    Post subject: Reply with quote

How about Allen socket or button head bolts? Wouldn't chip your wheels.
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Nexus Icon
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Joined: 26 Aug 2010
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PostPosted: 23:56 - 14 Oct 2015    Post subject: Reply with quote

binge wrote:
I am also going to need some new bolts to built the wheels up.
The old ones I had worked, but was not right.

I'd like some M8 bolts, around 20mm long. But they need to have a 14mm hex head on them, rather than 13mm.
This is because they located in the cut outs in the hubs, and are held still so you can drive the nut on to the back of the wheel.
13mm bolts just spin in the hole. I held the last ones by putting a flat blade screw driver into the gap around the bolt head, and the hole.

But this of course, is not right... And once my wheels are freshly powder coated in their new colour, I'd rather not chip them. Razz


How about M8x20 flange bolts, which would be a lot easier find, and you file a flat on one side of the flange?
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binge
Emo Kiddy



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PostPosted: 23:59 - 14 Oct 2015    Post subject: Reply with quote

Both good options.
I did consider the socket cap bolts, but wasn't sure about:

A, strength of the bolt against the hole. A hex head has more surface area than socket cap.

And B:, What it'd look like in a hex cut out hole.


Grinding a flat onto a flanged bolt could be over-time-consuming for me. I'm a little impatient, and there are 8 to do in total. Laughing
____________________
- 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 -
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Doovy
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PostPosted: 09:20 - 15 Oct 2015    Post subject: Reply with quote

binge wrote:
Split up with no Ex (for the third time)


I like single Binge... mechanical shit gets done Laughing
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World Chat Champion



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PostPosted: 13:44 - 15 Oct 2015    Post subject: Reply with quote

binge wrote:
Both good options.
I did consider the socket cap bolts, but wasn't sure about:

A, strength of the bolt against the hole. A hex head has more surface area than socket cap.

And B:, What it'd look like in a hex cut out hole.


Grinding a flat onto a flanged bolt could be over-time-consuming for me. I'm a little impatient, and there are 8 to do in total. Laughing


8?

Jeez, it's going to take less than 10 minutes total with a hand file, even if you buy stainless ones. That is impatience to the nth degree. In fact, I'd be amazed if you haven't moved on to the next post already. Very Happy
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binge
Emo Kiddy



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PostPosted: 16:29 - 15 Oct 2015    Post subject: Reply with quote

Gotta file 6 flats onto each one don't forget.
____________________
- 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 -
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PostPosted: 19:01 - 15 Oct 2015    Post subject: Reply with quote

binge wrote:
Gotta file 6 flats onto each one don't forget.


Then I've misunderstood what you need. Pop up a photo and I'll have a think what you could use.
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binge
Emo Kiddy



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PostPosted: 19:29 - 15 Oct 2015    Post subject: Reply with quote

The hubs have 4 holes drilled in them, which line up with 4 holes in the rim (2 piece wheels)

The holes in the hubs are 8mm, and they have a hexagon recess for the head of a bolt to sit snug into, so you can drive a nut onto the other end of the bolt, without having to hold it with a spanner.
This hex cut out, is 14mm. Meaning a 13mm bolt just spins in the hole.

https://img.webike.net/catalogue/18980/dax-00033.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 -
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binge
Emo Kiddy



Joined: 03 Jul 2004
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PostPosted: 19:31 - 15 Oct 2015    Post subject: Reply with quote

Also, some parcels arrived today.

Nothing too exciting.
Pair of replacement rear indicators, as one of them had broken. Couldn't get exactly the same again, so I replaced the pair. They're pretty damn similar to the fronts though.

Replacement rear innertube, as the valve on the old one was a bent type, and it used to rub on the rear brake drum torque arm. Wore the end of the valve down so much it let all the air out. Laughing


And my new carb. Which looks pretty cool. Look forward to getting it fitted and tested. Should run a bit nicer. May need to modify the choke mech though as it's lever operated, and the chaly has very restricted carb access once fitted as it sits within the frame.
____________________
- 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 -
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World Chat Champion



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PostPosted: 20:23 - 15 Oct 2015    Post subject: Reply with quote

binge wrote:
The hubs have 4 holes drilled in them, which line up with 4 holes in the rim (2 piece wheels)

The holes in the hubs are 8mm, and they have a hexagon recess for the head of a bolt to sit snug into, so you can drive a nut onto the other end of the bolt, without having to hold it with a spanner.
This hex cut out, is 14mm. Meaning a 13mm bolt just spins in the hole.

https://img.webike.net/catalogue/18980/dax-00033.jpg


You need something like this.

https://www.accuscrews.co.uk/full-thread-hexagon-bolts/19211-SEBF-M8-14-A4.html?uk_google_shopping=1&gclid=CMeKgLiZxcgCFQgXwwodkMMMpg
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binge
Emo Kiddy



Joined: 03 Jul 2004
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PostPosted: 21:03 - 15 Oct 2015    Post subject: Reply with quote

Not quite.
That's the correct thread size and pitch. Roughly the correct thread length (14mm). But the head head is still for a 13mm spanner. I need a 14mm spanner fitment.
Honda sell the bolts, but it's about £20 for the 8 bloody bolts!
____________________
- 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 -
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PostPosted: 23:25 - 15 Oct 2015    Post subject: Reply with quote

binge wrote:
Not quite.
That's the correct thread size and pitch. Roughly the correct thread length (14mm). But the head head is still for a 13mm spanner. I need a 14mm spanner fitment.
Honda sell the bolts, but it's about £20 for the 8 bloody bolts!


Dammit, I searched so many sites and then linked the wrong one. Now I can't find the one I was on. They mentioned selling Honda-style 14mm domed headed fixings but buggered if I can find it again - I was deep into Google at the time.

Sorry about that, I'll keep looking.

Edit: maybe I just got overexcited cos I can't find it again. I think I may have jumped the gun because I have just found a page which lists M8 dome nuts, referring to them as Honda-style, as well as M10 dome nuts which have a 14mm AF measurement. Helpfully, it doesn't say the spanner size for the M8.

It seems these things are specific to that one application. It's not uncommon for the Japanese to avoid using 13mm AF nuts and bolts (My Subaru has none) but they step down to 12mm AF for M8 threads.

I'll link the page with the Honda-style nuts but I'm not certain they're what you need.

https://www.inoxbolt.co.uk/zen/index.php?main_page=index&cPath=230_536

I'll also have a mooch around at work tomorrow as we have some really odd-sized stuff on the race cars.
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PostPosted: 19:25 - 19 Oct 2015    Post subject: Reply with quote

Well, after a couple of days looking around at work, it turns out we do have a fair few odd and bespoke fixings around. Unfortunately, nothing that fits the bill here.

I reckon you might have to bite the bullet and go oem.

The only thing I can offer is a nylon sintered piece with a 14mm hex and hole to suit a socket set screw so you could fill the space around a hex bolt.
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Cadbury
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PostPosted: 14:07 - 20 Oct 2015    Post subject: Reply with quote

How do you deal with keeping the frame number legible with powder coating?
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binge
Emo Kiddy



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PostPosted: 14:05 - 21 Oct 2015    Post subject: Reply with quote

The guys at BP Powder coating in Sittingbourne are the nuts.
They do all my bits. They're not the cheapest, but the quality is there. They take the time to to tape up all the threads and bearing seats etc.
They powdered lighter over the frame numbers so they're still visible through the coating. Cool


Oh, and I'll just leave this here...

Sorry to disappoint the homophobes.

https://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/12115542_164853627199004_5975248603877749503_n.jpg?oh=e3e854ad8bfd177f292a879de4f6a315&oe=56900100
____________________
- 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 -
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Doovy
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PostPosted: 15:00 - 21 Oct 2015    Post subject: Reply with quote

Shocked
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binge
Emo Kiddy



Joined: 03 Jul 2004
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PostPosted: 15:05 - 21 Oct 2015    Post subject: Reply with quote

This is the sort of thing I have in mind:

https://i.ytimg.com/vi/iwC8FvrSOfs/hqdefault.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 -
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pompousporcup...
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PostPosted: 15:08 - 21 Oct 2015    Post subject: Reply with quote

can you send me some of whateveritis you're smoking.. please?
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