Chinese, Japanese, Dirty Knees, Look at Theese...

Discussion in 'Some Assembly Required' started by Dirt Road Cowboy, Aug 4, 2013.

  1. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Chinese:

    [​IMG]


    Japanese:

    [​IMG]


    Dirty Knees:

    [​IMG]


    Look at These:

    [​IMG]

    [​IMG]


    What? You were expecting Sheri Moon Zombie? :evil
















    :lol3

    OK, I don't want to disappoint anyone:

    <iframe src="//www.youtube.com/embed/RXFXlj9jMHE" allowfullscreen="" frameborder="0" height="315" width="420"></iframe>


    Now, back to bike building. :deal

    This is the build report for my Lifan 140/CT200 Frankenbike!

    Her name is Linda. ( LIfan + hoNDA = LINDA ) :1drink

    If you don't like small bikes, or the jackassery that people do with them, or if you're a purist, then you won't have any fun here, so just go away. :huh

    So, if you're still here, and interested in the build, I'll go on with the story.

    I started buying parts for her over a year ago, as I could afford to. I'm forced to be a cheap bastage right now, so I needed to build, instead of buying a bike. I really did want to just buy one because it would have been easier, and I could have started riding sooner, but there's no way that I was going to pay the prices that people were asking for junk on CL around here!

    They're asking almost the same price for an old 80's or 90's bike, no title, needs work, easy fix, was running good when parked 7 years ago, etc., as the dealer is selling the new bikes for.

    So, I just decided to build one.

    This may not be as fun as one of RTW Doug's builds, but I'll try to keep you entertained as I go along. Maybe someone else out there is like me, and will be inspired to build their own bike too.

    The frame is a 1966 CT-200, which is a Trail 90. They didn't come with a 200cc engine, but they called them a 200? Confusing? Yeah, me too. That's probably why they finally started calling them CT-90s after a few years.
    I picked the frame up for around $40.

    The engine is a 140cc Chinese Lifan that I picked up last year for around $249 on bay. They have gone up a bit since then. Maybe it's just a summer thing? Anyway, they are still cheaper than a real Honda engine, and they're bigger with more power.

    The other parts are from different years, makes and models of bikes. Just various parts that I have been scrounging up along the way.

    The rear wheel is a 17" from a CT-90 or CT-110, and I'm going to put that double sprocket on it to give me a good gear range. The inner sprocket is 40 tooth, the outer is 68! That should be fun for off-road!

    This is my rear drive,
    It's got more than one.
    One is for streetin',
    One is for fun!
    :evil

    The front wheel is a 19" from something else. I forgot what, but I got the brake drum and axle with it, so I'll make it work!

    They will both be wearing some new Shinko Trials tires. :wink:

    I'm starting to work on cleaning up parts, and getting them ready for assembly, so I'll take pics as I go. Then, I'll be able to see what else I will need to get from Dr. ATV, or whoever else carries the parts to put these things together.

    The weather has really sucked around here lately, with temps over 100º, and humidity over 70%, and I haven't really felt like working in it much, but I'll try to keep plugging away at her.
    Even the mosquitoes are lazy. The other day, when I was out there, a couple of them called me over. In their Cheech and Chong voices, they were saying, "Hey man, if you're gonna be dooin' some chit out here, and you cut yourself, do us a favor an' come over here to drip the blood. We'll just lay here an' catch it, OK, dude?"
    And the other one said, "Yeah, man, and while you're at it, put some ice in it, man."



    Or maybe the heat was getting to me?

    :lol3


    (Sorry for the typo in the title!)
    .
    #1
  2. hmmwv15

    hmmwv15 young grasshopper

    Joined:
    Jan 25, 2011
    Oddometer:
    157
    Location:
    north-ish Georgia
    Really interested to see how that Lifan works. I'm in the process of rebuilding a thrashed 1978 Z50 and I can imagine how much more fun I'd have with an engine twice the size in it. But I do want the Honda back in it to keep it original. What can I say....


    In your case, Lifan all the way! That things gonna be fun. :evil
    #2
  3. Twin-shocker

    Twin-shocker Long timer

    Joined:
    Jan 28, 2012
    Oddometer:
    1,673
    Someone here in the UK has built a serious twin-shock trials bike using a Chinese Super Cub copy motor, and is currently leading his class in one of the 2 main twin-shock championship series on it. Only had a short ride on it, but it seems to me to be much more effective than most twin-shock bikes around currently.
    #3
  4. Kennon

    Kennon Been here awhile

    Joined:
    Aug 25, 2011
    Oddometer:
    323
    Location:
    Oxford, NT Hong Kong, Moscow
    I've seen the smaller speedway bikes using pitbike motors should be a good build, subscribed
    #4
  5. YamaGeek

    YamaGeek Ancient trailbike padwan

    Joined:
    Jun 24, 2007
    Oddometer:
    6,643
    Location:
    western oregon
    As owner of the LifanHaha, I approve of this thread..

    :thumbup

    [​IMG]
    #5
  6. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    I forgot to mention in the first post that this is my first time building a motorcycle of any kind. I have worked on them before, but never built one.

    I have built muscle cars from junkyard dogs, so I figured that I could take the same approach to building a bike.

    The first thing for me to do, was figure out what to build. It had to be something that was not completely obsolete, because I wanted to be able to find used parts that could be refurbished/recycled, and that there was a good amount of aftermarket support.

    I did not want to have every little piece custom fabricated. That kind of work, and cost, is way out of my league!

    I also knew that I wanted something small and light. Little trips to the store, and buzzing around locally, weren't much fun on the GL1000. I'll save that for 2-up trips and touring.
    A scooter seemed like it might be fun, but I didn't like the seating position. I had also thought of something like my old Honda CT70 that I had when I was a kid. That bike was a blast, and it was also the only reliable Honda that I ever had! Unfortunately (or maybe fortunately for me?), I decided that it was underpowered for what I wanted to use it for, plus, it would probably draw too much unwanted police attention around here.

    Then I came across the ride report that Nathan did about his trip with Dot, his postie bike. That seemed like a perfect small-bike solution since there is still a strong aftermarket following, and lots of used parts around. So, I did a bit of research, and found what I thought was the best combination of small bike, plus useable power.

    So, that's where it started. Thanks for following along!


    :freaky

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    #6
  7. Krasniewski

    Krasniewski I don't ride much.

    Joined:
    Feb 5, 2008
    Oddometer:
    1,264
    Location:
    LA - Lower Alabama
    Very cool - can't wait to see how she turns out!

    Nice score on the motor - it looks pristine. Good luck!
    #7
  8. C.John

    C.John to DOO or not to DOO

    Joined:
    Oct 14, 2011
    Oddometer:
    112
    Location:
    Far east Iowa
    Should be a fun build. Subscribed...
    #8
  9. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    So, back to the build…

    A lot of boring stuff is involved in doing one of these builds! :puke1

    Cleaning the frame. No pics because I really didn't think it was picture worthy, plus it was muddy and nasty and I didn't want to mess up the camera.

    But, just in case you need to know the process involved:

    Water.

    Soap.

    Scrub.

    Repeat until clean.

    :norton

    :lol3


    Sand the frame. Again, not worth taking pictures.

    Rough sand with 220 grit sandpaper.

    Wet sand with 220 grit.

    Sand with 400 grit.

    Wet sand with 400 grit.

    Rattle can grey primer. Again, not picture worthy.

    Sand with 220 grit sandpaper.

    Prime again.

    Sand with 400 grit.

    :1drink



    Now, time for the real paint!

    Woo-Hoo! Finally! :clap

    The color theme will be red, black and white. That is my personal favorite color scheme, plus it will hopefully stand out in traffic and keep my from being an unseen speed bump! :huh

    Remember, this whole build will be cheap (like me), so not professional paint jobs, or powder coating here!

    We're looking at Rustoleum Gloss Apple Red! :lol3

    For a rattle-can paint job, it's actually looking really good!

    [​IMG]


    [​IMG]


    Seeing her starting to look pretty will help keep me motivated to get this build done!
    (Then, I can start on one of the others!) :evil


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    #9
  10. WECSOG

    WECSOG Been here awhile

    Joined:
    Mar 30, 2013
    Oddometer:
    431
    Location:
    Just past the pavement's end in North Alabama
    Neat Cougar.
    Like you, I am building a Trail 90. Mine is a '76 CT90. I bought just the frame and triple tree, added forks, bar, controls and front wheel assembly from a junkyard XR100, bought a '71 CT90 engine with no compression, did a top-end rebuild, and now have the bike running and almost ready to ride.
    Needless to say, I'm subscribed!
    #10
  11. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Thanks. That's my daily driver.
    I bought it in 2006 (during the big muscle car fad when most any old car was overpriced) from a guy in Arizona from an ad online. All I had to go by was a few photos, and his word on it.

    It was rusted out, and in pretty bad shape, but I knew that I could get it looking good again, and that there were aftermarket places that had restoration parts, so I paid $2500 for it. :1drink

    My brother lives fairly close to where the car was, so I had him pick it up for me, then I flew out so that we could get it ready to bring to Texas.

    The upholstery was shot, there were big holes in the floorboards, no headliner, and the manual steering gearbox had almost 180º of slop in it.:huh

    We only had a week because of my schedule, so it was a rush to get it somewhat road ready. At the end of the week, I drove it 1300 miles to Texas. :D
    Considering that the trip was the only road test I did on it, the few minor problems I had on the way weren't really all that bad. I had a small set of tools, so I could fix anything other than a major breakdown.
    It did get a bit hot driving in August with no A/C, and no insulation to keep the engine heat out! :lol3

    The car gets a lot of attention since it's the only one like it here.
    I'm always having people stop and talk about it, telling me about the one they, or someone they knew had in high school or college.

    One gal even told me about losing her virginity in one! :lol3

    The fact that it is easy to work on, and get parts for, is the reason it's my daily driver. I wouldn't hesitate to drive it across the country, or anywhere.

    Those are the same reasons I chose to go with the CT for this build. :wink:


    I'm glad you got yours running. I think they're starting to get more popular these days. I have noticed more people buying CT90's, instead of bigger bikes. Either they like them for the pack mules they are, or they bring back memories.

    Glad to have you along!

    :freaky

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    #11
  12. theraymondguy

    theraymondguy Been here awhile

    Joined:
    Aug 5, 2013
    Oddometer:
    177
    Location:
    Niagara, ON
    I'm in the process of building a CA200 engine for a Rat SL70, and have just finished poking and stroking an ATC70 to 108, then cramming it into my CT70. Subscribed.
    #12
  13. MODNROD

    MODNROD Decisions, decisions

    Joined:
    Feb 20, 2009
    Oddometer:
    2,168
    Location:
    Midwest, West Oz
    I had a daily like that many years ago.
    1967 360 V8 Valiant.
    I was "between" interiors, and my daughter to this day still swears she melted the soles of her shoes on the bare steel floor.......the one directly above the collectors.
    This was over 10 years, you'd think she would have let it go by now hey? :lol3

    Cool build, sounds great. :clap
    #13
  14. WECSOG

    WECSOG Been here awhile

    Joined:
    Mar 30, 2013
    Oddometer:
    431
    Location:
    Just past the pavement's end in North Alabama
    That sounds like my '69 Firebird, too. Gutted interior, 350 (real Pontiac 350; not what most people think of when they hear 350) that I put a 4 bbl, headers and the shortest, largest core glasspacks I could find, and TH400 trans with a shift kit. I had a 455 I was planning to build up and drop in it, but the 350 ran so well that I never got around to it. Wish I still had it.
    #14
  15. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Well, not a whole lot of progress to report. Between work and other projects, I've been a little busy, but I'm trying to do something to her as often as I can. Even the small things add up!

    I am trying to get her somewhat together to at least be able to roll around, and look more like a real motorcycle, rather than a pile of parts. I hope to have her ready for some fall riding. :D

    I got to looking at the triple tree, and I decided that I'd never be able to use this lock, so it had to go:

    [​IMG]


    Time to make sparks! (Sorry, no pictures of the sparks.) :(:

    A few seconds later, the lock is off:

    [​IMG]


    Next, a little cleaning to prep for paint.

    You know the drill:

    Soap

    Water

    Scrub brush

    Repeat until finished.

    A quick sanding, a little primer, then some rattle-can gloss black paint.

    Triple tree painted:

    [​IMG]


    I'm still not positive what the tree originally was on. I'm pretty sure it was a Honda 125, or 175. It works well with the CT head and ball bearings though. :nod

    I got a little impatient, as usual, so I test fitted the engine and frame just to see how they'd look together.

    Test fitting engine and frame:

    [​IMG]


    I think they go together nicely! :clap

    There is a little problem. I think the crankcase vent on the back of the engine is hitting the frame, and the lower bolt won't quite line up.
    A couple of whacks with a BFH should take care of it! :lol3

    I also ordered some parts for the ignition last night. I really want to get her going! :ricky

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    #15
  16. 4doora

    4doora Moped guy

    Joined:
    Jun 19, 2013
    Oddometer:
    29
    Location:
    NH
    I can't wait to see the progress you make on this. I'm going to be building a similar bike soon.
    #16
  17. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    Sorry guys, I've been slacking a bit on the report. :norton

    I spent a bit of time making some work space in my shop so that I wouldn't keep tripping over everything. I've got parts for 4 bikes in there, plus all my tools and equipment, so space is a bit tight.

    I did get a little progress made on the CT though. I had to do a bit of cutting and grinding on the frame to get the engine to bolt up. The little 4 1/2" Skil angle grinder that I bought at Wal-Mart really made quick work of it. :wink:

    If you want to do any of these types of projects, and you don't have a small angle grinder - get one! The cheap ones from Harbor Freight would probably work too, but I don't have a HF store near me, and I don't want to mess with return shipping if it breaks, so I spent the $30 at Wally World. Then, get the $3 cutting blade for it, and you'll be able to cut, or grind just about anything you'll need on a bike project.
    I have an old grinder that my dad gave me when I was 14. It is a heavy-duty (and very heavy at almost 20lbs.) all metal one that came from the oil fields in the 1960's.
    The new ones are lighter, and work well for bike building. OK, enough about that.

    I tried to take as little as possible off the frame because I didn't want it to look like a hack-job. I made some small cuts, and then ground down to the cut. Then, I test-fitted the frame to the engine, and repeated the process until it bolted together. :deal

    The pictures of the actual grinding didn't turn out because my camera was set on macro, and everything was blurry, even the sparks hitting my OSHA-approved bare feet! :lol3

    So, here are the after pictures. you can see how I tried to keep the curves flowing.

    Here is the left side:

    [​IMG]


    Another up close:

    [​IMG]


    Here is the right side:

    [​IMG]


    And a close-up:

    [​IMG]


    It took a little longer because of all the test fitting, but It will look pretty good when I get it touched up and repainted.

    The rest of the work has been the tedious job of cleaning parts to prep for paint. :puke1

    I also cleaned up the wheels so that I could see how the new Shinko trials tires will look on them.

    (Those leaves are from last fall. I hate yard work! :rofl )

    Not too bad:

    [​IMG]


    Here is a close-up of the front:

    [​IMG]


    The front wheel is a 19" wheel off an older (pre-disk brake) Honda 175 (I think). It is in pretty nice condition.

    Here is a close-up of the rear:

    [​IMG]


    It is an original 17" CT 90 wheel from the 60's, so it is in a bit rougher shape. I wanted to go with the original hub to be able to use the dual sprocket rear drive. Some of the spokes are a bit rusty, but I'm not going to replace them yet, just in case I want to change rim sizes. I'm starting with the 17 & 19, but I may go to a 19" rear with a 21" front. I'll have to see how I like the current set-up first.



    That's about it for now, other than a lot of cleaning and sanding. Bike building is a dirty job!

    [​IMG]


    :lol3

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    #17
  18. WECSOG

    WECSOG Been here awhile

    Joined:
    Mar 30, 2013
    Oddometer:
    431
    Location:
    Just past the pavement's end in North Alabama
    Looks like it's coming along nicely! :thumbup
    #18
  19. hugemoth

    hugemoth Long timer

    Joined:
    Sep 6, 2007
    Oddometer:
    3,081
    Location:
    In the TARDIS
    You'll like the Lifan 140 if you don't mind putting some umph into kick starting it, and you won't need the 68 tooth sprocket. With a 15/40 sprocket set it'll climb anything as long as you can get traction and keep the front wheel down. I now have over 11,000 miles on my CT90/140 and the only engine problem I've had is the shift drum stopper screw working loose causing it to jump out of gear (easy fix).
    #19
  20. Dirt Road Cowboy

    Dirt Road Cowboy Sometimes I'm A Jerk

    Joined:
    Feb 19, 2011
    Oddometer:
    505
    Location:
    Tyler, Texas
    I don't think kick starting will be too bad. I used to kick start my old Yamaha 360, my 72 Sportster, and my BSA, so I hope I can kick a Lifan 140! :lol3

    I'll probably change the front sprocket to a 17 or higher to get the road speed up a bit. I like having the option to play around with the different combinations with the dual rear. Maybe I'll change them out to something like a 36 and a 50ish.

    I'm glad to hear that your Lifans are doing good. Your posts are what encouraged me to go the Lifan route instead of trying to find a good Honda engine.

    Thanks hugemoth, and thanks to everyone else for following along and giving your encouragement! :freaky

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    #20