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Old 03-30-2013, 10:27 AM   #16
muttley92 OP
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Joined: Jan 2013
Location: United Kingdom
Oddometer: 66
Frame change

Since the existing bike was cat B, the DVLA in their wisdom dictate that it cannot go back on the road without being renumbered and passing a single vehicle allowance test (140) So I opted for a second hand frame (75) despite being told they are identical, in actual fact the swing arm bushes are 2mm different so they didn't fit... I had to order one for the earlier shape bike and that worked fine
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Old 03-30-2013, 10:29 AM   #17
muttley92 OP
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next step

After the frame change I sorted out some cooling hoses to get it running on.


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Old 03-30-2013, 10:36 AM   #18
muttley92 OP
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Frame oil

Since the standard bike uses the front frame tube as an oil resevoir and probably as a heat sink I though it necessary to have some sort of oil box to bring the capacity back up and dissipate some of the heat.
this is a cardboard mock up to fit nicely in the frame


and the stainless version


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Old 03-30-2013, 10:45 AM   #19
muttley92 OP
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Pogress

The bike with everything so far fitted, though the plastic tank inside the cover fouled on the engine so will have to do something about that.

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Old 03-30-2013, 10:47 AM   #20
muttley92 OP
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oil tank

Got some bosses on the oil tank to suit the standard lines.


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Old 03-30-2013, 10:51 AM   #21
muttley92 OP
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Got a nice can

This is a race can with baffle from Pipewerx, top quality, weighs nowt and they will make them to a specified length and inlet diammeter.
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Old 03-30-2013, 10:58 AM   #22
muttley92 OP
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Oddometer: 66
link pipe and exhaust

I made the rest of the exhaust pipe.





Then decided that I (and the rest of everyone i know) hated it, so it went in the bin and I started again with this in mind
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Old 03-30-2013, 11:02 AM   #23
Droptarotter
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Joined: Jul 2007
Location: Cloverdale
Oddometer: 1,175
Looks like it is coming along nicely.

Couple of questions on the oil tank............

What is the capacity?
How will you drain it?
How will you refill/bleed the tank after an oil change?

Keep the photos coming!!
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HP2 Sport, R1200S, R100S, KTM 640 Adventure, KTM 520 EXC/Motard, Yamaha RZ350, Hodaka 125 Wombat
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Old 03-30-2013, 11:04 AM   #24
muttley92 OP
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Oddometer: 66
the Loom

I don't have any photos but I cobbled together a loom from the stock 640 one sufficient to let it run. Would it start? Would it hell! The starter motor span up but the engine wouldn't turn over. This was traced back to the starter clutch and subsequently replaced. This was the first proper engine test
http://www.youtube.com/watch?v=7gLFKLdQTKI
It's a tad loud but I hadn't finished the exhaust at this point...
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Old 03-30-2013, 11:07 AM   #25
Droptarotter
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Location: Cloverdale
Oddometer: 1,175
I prefer the second muffler location also...........hey, how come you did not run it up the right side of the bike??

Cheers
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HP2 Sport, R1200S, R100S, KTM 640 Adventure, KTM 520 EXC/Motard, Yamaha RZ350, Hodaka 125 Wombat
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Old 03-30-2013, 11:08 AM   #26
muttley92 OP
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Quote:
Originally Posted by Droptarotter View Post
Looks like it is coming along nicely.

Couple of questions on the oil tank............

What is the capacity?
How will you drain it?
How will you refill/bleed the tank after an oil change?

Keep the photos coming!!
The capacity is approximately 750cc.
The stock frame tube is about 600cc and i thought a little extra wouldn't hurt.
To drain it I will remove it and upend it.
I don't need to bleed it, both the inlet and outlet are on top, it fills up, pressurises itself and flows out to the standard oil return.
As for the exhaust, the chain is on the RHS of the bike and I didn't want clearance issues. The standard RS 125 exhaust is LHS exit so mine is too.
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Old 03-30-2013, 11:16 AM   #27
muttley92 OP
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The bodywork

Since the nose cone was in 4 bits and i HATE the colour I decided to fix it


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Old 03-30-2013, 11:19 AM   #28
muttley92 OP
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The tank

Since the tank fouled the new motor I cut the bottom out and inverted it, I will have it plastic welded later.



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Old 03-30-2013, 11:24 AM   #29
muttley92 OP
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The exhaust

My Father found a link pipe for a bike unknown at a jumble sale that 'looked about right' was a total of 6. Modified it a bit (cut the end off) and rewelded it into this.


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Old 03-30-2013, 11:27 AM   #30
muttley92 OP
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Oddometer: 66
The nose cone side panels

I also painted the side panels





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