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Cheeky Chaly Rebuild

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binge
Emo Kiddy



Joined: 02 Jul 2004
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PostPosted: 20:24 - 22 Nov 2015    Post subject: Reply with quote

The genny gives out amples of power. But I want an electric start. Razz

Not only that, the clutch slips slightly when kick starting from cold. Being a primary clutch engine, the kick start has to turn the engine over through the clutch, and being that it's a centrifugal clutch, the lock-up feature doesnt seem too up to the job for the higher compression engine.

The electric start is chain driven straight onto the crank behind the flywheel. A much more direct way of starting.
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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
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binge
Emo Kiddy



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PostPosted: 17:42 - 25 Nov 2015    Post subject: Reply with quote

Well today was my day off.
I decided to take Chaly for an MOT.
My friend usually tests it for me, and it's generally quite a laid back MOT. But he was not around today, so I used a local MOT station to my house.

The two guys testing it had a bit of a giggle, but once they worked everything out, they were happy enough to put a clean sheet on it. Well chuffed! Thumbs Up


http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/s720x720/12311043_182081618809538_4767181769910431110_n.jpg?oh=2f0dd114f5b8f4d15a2d3cd605bbfc34&oe=56E5FA22


http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/s720x720/12246869_182081672142866_8897581651846802193_n.jpg?oh=ddecbaa629d82103075b3585abc88cb3&oe=56E1544C



I insured it with MCE, Fully comp with break down cover etc, for a grand total of 101.40.
TAX, is of course nice and cheap, at 17. Although the cheeky bastards have put it up. The last time I TAXed it, I only paid 16! Laughing


And I spent the day riding it around. I've covered about 40 miles on it. Used about 1/2 tank of petrol.

Left a couple of 125cc 4t learner bikes standing at the lights. Was a good giggle.
And had a few Traffic-light GPs with some big sports bikes too. Dude on an R6 seemed a little shocked at how quickly it took off. Good times!



It needs a new front sprocket, a bigger one. As it's currently topping out at around 40mph (just over 60kph).
It'll easily pull way faster as it's hitting 60kph like it's hitting a wall, literally on the limiter.

Gonna jump the front sprocket up a few teeth, and hopefully improve the top speed to about 55mph. It pulls away with ease, in 3rd gear, and will go with a bit of gas in 4th currently.
____________________
- 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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buaan
Two Stroke Sniffer



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PostPosted: 13:48 - 26 Nov 2015    Post subject: Reply with quote

Cool, nice work! Cool
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mysterious_rider
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PostPosted: 14:52 - 26 Nov 2015    Post subject: Reply with quote

I remember 17-34t i think on the monkey. With ten inch wheels. Wasnt too bad.
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UncleBFester
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PostPosted: 15:48 - 26 Nov 2015    Post subject: Reply with quote

I'll come right out and say it ....

I REALLY like that Embarassed
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Kris
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PostPosted: 16:06 - 26 Nov 2015    Post subject: Reply with quote

binge wrote:
Well today was my day off.
I decided to take Chaly for an MOT.
My friend usually tests it for me, and it's generally quite a laid back MOT. But he was not around today, so I used a local MOT station to my house.


Don't know why but that looks like Med Spray in Chatham (Luton).
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stevo as b4
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PostPosted: 16:21 - 26 Nov 2015    Post subject: Reply with quote

Thumbs Up for the MOT and more so for pasting other bikes too!

It should do a bit over 55mph with 10bhp and the right gearing shouldn't it?

I remember my mate said his C90 delivery bike used to do 55mph on the ring road, and the occasional wheelie too! Laughing
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binge
Emo Kiddy



Joined: 02 Jul 2004
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PostPosted: 19:00 - 26 Nov 2015    Post subject: Reply with quote

mysterious_rider wrote:
I remember 17-34t i think on the monkey. With ten inch wheels. Wasnt too bad.


I'm gonna be running 18:28 - Hopefully it wont be too tall. It's currently on 14:28 and ridiculously short!


UncleBFester wrote:
I'll come right out and say it ....
I REALLY like that Embarassed


Haha! Me too. Wasn't sure at first. But must have turned so many heads, got loads of waves. And the girls seem to love it!
They probably think I'm a shirt lifting potential new best friend. Laughing


Kris wrote:

Don't know why but that looks like Med Spray in Chatham (Luton).


Sure is. Wicked bunch of guys. About 2 mins from my house.



stevo as b4 wrote:

It should do a bit over 55mph with 10bhp and the right gearing shouldn't it?


I'd say 55mph is quite reasonable. If it pulls 50mph without reving it's tits off I will be happy.



Amazing what a filter does. Look at that colour! Razz

http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/12313588_182334098784290_2651198657571419432_n.jpg?oh=ca10fd3c5ef645e526e6d293c6ac5ed3&oe=56D933FA
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- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
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mysterious_rider
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PostPosted: 20:02 - 26 Nov 2015    Post subject: Reply with quote

Just found the specs to one of my monkeys . with 125 lump 17-26t and 8" wheels i got a cruise of 40-45mph and top of 60mph.

If running on ten inch wheels you should get about 70?.

Should be good.
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Kris
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PostPosted: 21:16 - 26 Nov 2015    Post subject: Reply with quote

binge wrote:

Kris wrote:

Don't know why but that looks like Med Spray in Chatham (Luton).


Sure is. Wicked bunch of guys. About 2 mins from my house.


Hah! Cool.

I get all my MOTs done there too. I used to live round the corner myself.

Very Happy
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Paddy.
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PostPosted: 21:46 - 26 Nov 2015    Post subject: Reply with quote

Cool as fuck Laughing

Do you know anyone who wants a legal monkey bike at all. I'd ride with you on mine but to be honest the bike buzz has gone... I now get a lift or ped to work Sad
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binge
Emo Kiddy



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PostPosted: 17:43 - 29 Nov 2015    Post subject: Reply with quote

So yeah...

Chaly does 115kmh with the new front sprocket on. Fucking LOL!
Boiled my front brake off in no time. Embarassed

http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/12310651_183976575286709_7965588155809799619_n.jpg?oh=e5440c00cb3c5f29d2336d0add6fc50c&oe=56F45C93
____________________
- 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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Paddy.
Red Rocket



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PostPosted: 17:44 - 29 Nov 2015    Post subject: Reply with quote

Shocked that is pretty quick.
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binge
Emo Kiddy



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PostPosted: 17:58 - 29 Nov 2015    Post subject: Reply with quote

The state of tune this little Thumpstar engine is in, is really impressive.
It knocks the spots off of a 125cc Lifan type engine. Really impressed at how much grunt it's got.
____________________
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- 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



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PostPosted: 18:27 - 29 Nov 2015    Post subject: Reply with quote

This is a clip of the Chaly cruising up Dargets hill.
Anyone who knows the area will understand how steep it is.
Anyone who does know. This hill is the sort which will reduce a Speedfight 50 or similar, to a brisk walking pace. Laughing

https://www.facebook.com/Binge.Jammin1987/videos/184004621950571/?l=9117982607670762335
____________________
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- 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
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PostPosted: 22:32 - 30 Nov 2015    Post subject: Reply with quote

Sounds like a beast! Smile
115kmh is probably a bit more than my speedfight 100 ever did and that was after 600 worth of tuning gear and setting up thrown at it!

That little motor must have a good few bhp for 120cc!
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binge
Emo Kiddy



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PostPosted: 22:46 - 30 Nov 2015    Post subject: Reply with quote

You've also got to consider how light the thing is. I can pick it up. Razz
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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
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binge
Emo Kiddy



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PostPosted: 23:57 - 01 Dec 2015    Post subject: Reply with quote

https://www.facebook.com/Binge.Jammin1987/videos/184576405226726/?l=8515978687717265710
____________________
- 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



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PostPosted: 14:57 - 06 Dec 2015    Post subject: Reply with quote

Had a great ride out today. Went for a run down to Tunbridge with a few friends. One Monkey bike, Another Chaly, and a pal on a road legal pit bike.
Also Syrus on the trusty CG125 came out for the hoon! Thumbs Up

http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xlf1/v/t1.0-9/12316093_187100671640966_4077269828375898982_n.jpg?oh=6e2b2898071792a7407be780a8c882f5&oe=571F9B1B

http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/12321484_187072514977115_22731317077451565_n.jpg?oh=b5ea63e949f4ed1c477d8bb91128366d&oe=56E7405E



Chaly went very well. The Monkey bike had a 125cc manual engine fitted. Had a slight lead on mine from the get go, but Tom, the owner is probably 3 stone lighter than me. Laughing

The red Chaly has a YX140 stuffed in it, so does the road legal pit bike.
Although speed wise, my Chaly was doing alright with them.
____________________
- 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



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PostPosted: 16:27 - 06 Dec 2015    Post subject: Reply with quote

https://www.facebook.com/Binge.Jammin1987/videos/187147778302922/?l=414134570023087645
____________________
- 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



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PostPosted: 15:21 - 19 Dec 2015    Post subject: Reply with quote

Fun sort lived. Crying or Very sad

Today, the first motion shaft gear decided to shit a load of it's teeth off, and into the sump. I think the clutch basket gear has gone too.

Thankfully they've stuck to the sides of the engine, and not destroyed anything.
I'm thinking it's because the top end is too meaty for the little 50cc semi-auto gubbins.

Options are, to either replace broken bits, and ride more sensibly.

Try one of the CRF50 billet clutch baskets, and see if I can modify it to take the semi-auto inserts. Can't be that much different I don't think.
Or convert it back to manual.
If I am doing the last bit, and going over to manual. I may as well just swap the entire engine out for a YX140, or even another Lifan 150cc (Daytona style) engine, with the integrated oil filter. Lovely engine, and plenty of power.



Booo.

Might just replace the broken bits for now, as I was hoping for a boxing day ride out.
____________________
- 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: 17:30 - 19 Dec 2015    Post subject: Reply with quote

I hope you can find a strong enough semi auto solution for it, as I think being an auto clutch with a 3speed box really suits it TBH.

You must have a lot of power from that Thumpstar engine, as C90's are about 7.5bhp and never seem to have any gearbox problems?
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mrbox
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PostPosted: 05:09 - 20 Dec 2015    Post subject: Reply with quote

I also think semi auto would be cool to keep if you can find a way. bike looks awesome Thumbs Up
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binge
Emo Kiddy



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PostPosted: 14:26 - 20 Dec 2015    Post subject: Reply with quote

Fitted a smaller rear sprocket (28t). This is the sprocket that required my mate Gaz to machine the hub to allow a chain to sit on the sprocket properly, because the area on the sprocket where the chain sits, is actually smaller than the hub it's self. Laughing

http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xla1/v/t1.0-9/12346514_192008351150198_2337913558988347568_n.jpg?oh=cf1c4082c313ef318866a47c8e450952&oe=5714F289


http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/12376471_192008364483530_6408791658491896185_n.jpg?oh=dad426ad4d46bfc98cf0379ad5c8e88e&oe=56E09E22


Nursed it up to work, stuck it up in the air on a ramp, and pulled the side off the engine again:

http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xft1/v/t1.0-9/1929903_194693340881699_6599203263981158389_n.jpg?oh=752eb938603ff077e1a61311fa459d15&oe=56E0B548


Culprit, broken teeth on the input shaft drive gaer. And a mashed Crank gear which sits behind the clutch basket.

http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xla1/v/t1.0-9/12376446_194693377548362_3716532706974698781_n.jpg?oh=50bcd619dc6870100e73e375272d505e&oe=56D537CC



The 50cc Semi Auto clutch gear which sits on the crank shaft, meshes with the main gear which has a missing tooth.
These were both from the 50cc Semi auto engine.
I've modified the crank gear from the Thumpstar 120, to sit in the back of the Semi Auto clutch from the 50cc, and used both input shaft gear, and crank gear from the Thump. So hopefully those two bits will now withstand the extra power.

The gearing is slightly shorter too, allowing it to carry the smaller rear sprocket better. Razz


Re-filled with a good quality oil:

http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xtl1/v/t1.0-9/12360047_194693404215026_2199441758335694209_n.jpg?oh=256ddd4a4b7fb0e20448caed33d3fa34&oe=5716BEF2


And went for a ride.

http://scontent-lhr3-1.xx.fbcdn.net/hphotos-xat1/v/t1.0-9/12391027_194723947545305_8165481466488113473_n.jpg?oh=24aa4d343ae4de0c3ab5c1a0036c417f&oe=56DAE815



If it all goes to shit again, TBolt USA sell stronger gears, and they also sell these billet clutch baskets which are for a semi-auto engine.
They claim to be able to hold up to the power from the CRF50 engines, which have the Takegawa 124cc big bore kits, and cylinder heads.

We shall see. Laughing


I don't think the Thump 120 lump is overly powerful. They claim 9 to 10bhp from factory.
____________________
- 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: 02 Jul 2004
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PostPosted: 20:58 - 08 May 2016    Post subject: Reply with quote

Quick update on the little bike.
Done about 1500 miles on it since the rebuild.
It doesn't take too well to long rides or bad weather. It's a real Carpet Queen. Laughing


This evening I tinkered while my GF was doing my Mammas Nails.
Took the opportunity to get some garage time in. Razz

Was getting fed up with the ugly thumpstar engine cases.
So stripped it all back to the bare engine:

http://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/13124955_275915609426138_1332074759786886065_n.jpg?oh=4ad94790727843087daaf1b6533594f9&oe=57AD1B6A


And fitted a Honda CRF50 start plate, 5 coil stator, flywheel, and ign cover.

http://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/13164452_275936172757415_7260286148070532129_n.jpg?oh=ef4256f59f96bbf5b82741f58f5d16a9&oe=57AE6722



Took it away with us to Hastings last week:

http://scontent-lhr3-1.xx.fbcdn.net/t31.0-8/13072814_272711816413184_8649398196466854928_o.jpg


And went on the MayDay run

http://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-0/p206x206/13094359_272497093101323_1875628803890079383_n.jpg?oh=03f4074a1dd5fc6b205c1eaca1409705&oe=579FCAAC


http://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/13076846_272595196424846_1010700783955076215_n.jpg?oh=6ffb689b97e9033e9eaefbc7192762c7&oe=579E285B


And Cassie likes it, quite a lot.
So the next plan is to dig the Honda Caren out, and rebuild it. Baby Blue, with a little basket on the front! Very Happy

http://scontent-lhr3-1.xx.fbcdn.net/v/t1.0-9/13178645_274936096190756_804005271708033575_n.jpg?oh=9b4da0885765d03d02c00052ea67829c&oe=57E3CFD6
____________________
- 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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The last post was made 1 year, 219 days ago. Instead of replying here, would creating a new thread be more useful?
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