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generatorshovel
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Date Posted:05/19/2007 8:15 PMCopy HTML

Well, I've given up cigarettes to fund the salt habit, and things are moving along smoothly.The FZR head and barrell lost No4 cylinder,(Yamaha's loss, Honda's gain)the water galleries and oil returns have been plated, the crankcases are nearly finished their stay @ the welders shop and will be decked soon (its a "laydown" engine now.aka ct110 style), the crank has been modified to take the FZR rod (slipper big end bearing), the piston (FZR) is booked in for a ceramic crown coating, and I've contacted a friend who'll balance it all for me.The FZR cams have been shortened, with2 ofNo3 cyl's lobes being reduced to a 23mm circle where the oil seal will run , and the other 2 lobes are gone, leaving a 22mm camshaft extension to be used with outrigger bushings which will double as the oil feed to the cams.The belt pulleys are on their way from Gates, for added "bling"CDI ign is on the wish list (Boyer Bransden,,$700,,ouch, with adjustable rev limiter and special coil)Dunno 'bout it being ready for 2008's timetrials, 'cos I need to build a new frame yet, and source some better wheels, and speed rated slicks,,and so on , and on,,,,,,but,,ya never know? 'till ya try.Tiny
Swiss #31
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:06/08/2008 6:23 PMCopy HTML

How are things coming Tiny?

Any progress?

Swiss
generatorshovel #32
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:06/09/2008 7:02 AMCopy HTML

Yeah, progress is happening,although I had to drive a 700 mile round trip to get some tyres for it (I 'spose I could have waited, but my daughters 21st b/day party was on @ the same place)
NOW we'll have some progress, ride height, swing arm, gearing choices, seating position sorting is on the "to do " list.
Nearly have the CDI $'s saved, so that will be another job soon.
Theres a heap more frame pics in my photobucket, mainly to show the DLRA scrutineer and get the ok to continue, its much the same as the previous pics I've posted though, just a few gussetts and cross members added.
I spent 2 weekends bashing an old alloy road sign into an air deflector / carb cover that sits under the frame backbone(s), but thers no pics of that yet.
Tiny
generatorshovel #33
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:06/13/2008 9:22 AMCopy HTML

[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/dreamin.jpg[/IMG]
Swiss #34
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:06/14/2008 3:57 AMCopy HTML

Lookin' good Tiny, just like old Burt Munro!  Maybe you should put an Indian sticker on it before you run it!

Swiss
Motoracer838 #35
  • Rank:Gold Member
  • Posts:121
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:06/14/2008 1:47 PMCopy HTML

Tiny, I gotta tell you, you look like a man thats having too mugh fun, thats lookin' so cool. keep up the good work.

Chher Beers n Gearz. Joe
generatorshovel #36
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:06/29/2008 9:05 AMCopy HTML

More progress,,,,and a decision was made,,,I have a little more ca$h saved, but not enough, as usual, so I decided, to keep progress happening, I'd contact the place I emailed 13 months back, to see if the CDI had gone up in price,,well, it had GONE DOWN !
I had planned on purchasing the CDI pickup, and black box, and getting the rev limiter and coil later, and using the spare $'s to get a mandrel bend for the header pipe, and a Davies Craig elec booster pump.
The best news was this,
http://www.pazon.com/ignition-system/smart-fire-crank-trig-single-4-stroke
CDI, coil AND rev limiter all for $530 Oz $'s (not the Boyer Bransden I had planned on using)

I've also finished the swing arm and I'm ready to machine up some rear axle spacers, and a sprocket spacer / adaptor / extra bearing carrier.

I hope it ends up more reliable than my 41 y/o Harley, lol, which broke down IN THE SHED today ! (spat out a front primary pulley bolt, which then had an argument with the belt guard mounting bolt, and sounded MUCH worse than it was (looks),,,,another job to add to the never ending list of " to do's "
Tiny
generatorshovel #37
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:07/13/2008 7:25 AMCopy HTML

Heaps of progress this month, things are really coming together, The ignition Hall effect trigger is fitted, the rotor that triggers is was a pain to make,,the swing arms finished (except chain guard mount, and disc brake master cylinder, which should be here in a week, with the water pump and a mandrel bend for the exhaust header)
Steering damper is on , seat frame rail No1 is in place , and the seat base should be done this week also.
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/July%2008/roller.jpg[/IMG]
Here's the link to the rest of the pics
http://s156.photobucket.com/albums/t24/generatorshovel/July%2008/
Tiny
generatorshovel #38
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:07/20/2008 7:19 AMCopy HTML

Time to clog the forum with some more update pics.
There's lots to do, and it seems I better make a list of "to do's", so I get myself orgynised, or I'll keep going around in circles like I did this week.
Iv'e been wasting time mocking up the bodywork with cardboard when I should be setting up my $30 Ebay twin spot slave and master cylinder, setting up the exhaust header and finishing the rear tail section, but thems the breaks.
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/mock.jpg[/IMG]
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/mock2.jpg[/IMG]
Tiny
Swiss #39
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:07/22/2008 7:06 PMCopy HTML

Lookin' really good.  It is the details that take the time.  Don't shortcut the build quality!

Swiss
generatorshovel #40
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:08/10/2008 8:13 AMCopy HTML

Here are a few more pics (thanks Swiss)
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/meg.jpg[/IMG]
http://i156.photobucket.com/albums/t24/generatorshovel/10-8-08008.jpg
http://i156.photobucket.com/albums/t24/generatorshovel/anti-reversion.jpg
http://i156.photobucket.com/albums/t24/generatorshovel/pipes.jpg
http://i156.photobucket.com/albums/t24/generatorshovel/meggybitz.jpg
http://i156.photobucket.com/albums/t24/generatorshovel/SAl.jpg
http://i156.photobucket.com/albums/t24/generatorshovel/armr.jpg

Tiny
Swiss #41
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:08/10/2008 7:07 PMCopy HTML

OK Tiny, how long is your headpipe and what rpm are you tuning for peak power?  Your AR is small but should work.  A little late to tell you but when building your frame, gussets that are at tubing joints should be welded on the sides of the tubing and not the centers as you did.  It is stronger to place them on the side edge rather than between the tubing.

Still looking good and coming along.

Swiss
generatorshovel #42
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:08/11/2008 8:24 AMCopy HTML

The header pipe is as yet uncut to length (18" from port, if I remember correctly) and the AR is as big as the mandrel bend would stretch, without splitting.
Thanks for the belated gusset tip,,lol, next time.

Power hopefully will be strong from 9,000 up to where ever it feels like its still pulling, even if I have to close one eye and NOT look @ the tach for a while.

Tiny

generatorshovel #43
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:08/31/2008 7:52 AMCopy HTML

Yeah, I miss the meccano set I had as a kid.
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/Fside.jpg[/IMG]
Tiny
generatorshovel #44
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:10/10/2008 10:35 AMCopy HTML

I thought I'd let all know I'm still working flat out in the creation station , I managed to have yet another complete engine teardown, thanks to the crankcase gasket deciding it would squash up a bit, in the 3 months since it was assembled last, just enough to make the input shaft gear cluster bind, and make spinning the countershaft difficult to turn.
  That job's completed, as is the frame, paint and all !
The ignition (pazon CDI) is mounted, and timed
Swing arm , disc caliper and master  cylinder are fitted (and work,,lol)
The seat (belly rest ?) has been upholstered
Exhaust ,,finished, and painted,,,,

Tomorrows job is fitting, and supporting the diffuser block, of the oil lines, weld the water outlet tube/water temp sensor adaptor, and mount the water pump.
 
I won't post any pics until I have some that you have'nt already seen , even though it looks REAL purdy when painted.

I feel the "startup party getting close now
Tiny
generatorshovel #45
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:10/26/2008 9:57 PMCopy HTML

Another update, for those that are interested, and following the build
I'm at the wiring stage now, which includes fabricating a kill switch mounting block within easy thumb reach, part of which includes the leftover flesh, a result of drilling a 6mm hole in my left hand
The cooling system is ready for coolant, the CD! now lives behing the seat, with a few electrical components, the clutch cable is fitted, carb jets are ordered (life sux when ya live miles from anywhere some times)
It's even has a kickstand now,,theres technology for you !
All things going well, it should be ready for its first fire up in 2 weeks, and I plan on making a short video video clip of the event, which I'll post here.
Tiny
Ex_Member #46
  • Rank:
  • Posts:0
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:10/27/2008 5:44 AMCopy HTML

Great progress Tiny, Ive been following your project from the start and Im getting excited about hearing it run, good luck mate and keep up the good work.
Dean
generatorshovel #47
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:11/02/2008 10:32 AMCopy HTML

The birth grows closer, the startup party invites are out, next saturday is (hopefully) the BIG DAY !
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/10-8-08010-1.jpg[/IMG]
Tiny

Motoracer838 #48
  • Rank:Gold Member
  • Posts:121
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:11/02/2008 2:42 PMCopy HTML

Thats strange I didn't get my invite, with prices what they are, I couldn't afford to go anyway. I will have to make it to the great white dyno when you bring it to shatter the existing record!!!

In the mean time, how about recording the startup and putting it on u tube for us to see? The bike is looking really cool.

If you can't see the future,
your not driving fast enough! Joe
generatorshovel #49
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:11/08/2008 10:13 AMCopy HTML

[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/whysmile.jpg[/IMG]
Why the smile?
all is revealed in these links
http://s156.photobucket.com/albums/t24/generatorshovel/?action=view&current=startup.flv
http://s156.photobucket.com/albums/t24/generatorshovel/?action=view&current=started.flv

The good news,,,,,,,,it runs,,,,oil pressure smack bang on the 55 PSI that was planned, and nothing has fallen out of the engine (yet), after running for 3 non consecutive minutes.

The bad news,,it'll only run @ part throttle, with the choke on, but thats a minor detail that'll be sorted later,,,oh,,and the kickstarter return spring broke (bugga,,thats spring No 2 , in 30 kicks !)

Ex_Member #50
  • Rank:
  • Posts:0
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:11/08/2008 3:00 PMCopy HTML

Tiny,
She sounds like a beast, keep the updates coming, Im waiting on some rolling test footage now.
generatorshovel #51
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:11/09/2008 6:56 AMCopy HTML

I'm lucky it did'nt turn into a bomb,,,,seems I mistakenly plugged the carby float bowl breather, causing the pressurised bowl to force fuel everwhere, including down the inlet port (1 bowl full @ a time overnight, and each time I had the fuel pump switched on, which was only on the last run, as I relied on just a float bowl full on the 1st 2 runs), and slowly trickeling past the rings, and into the crankcase, diluting the $15 / litre oil to a dangerous combustable mix !
It should'nt have run at all,,,,I'll stoke it up again once the fuel vapors have vacated the crankase, and I replace the oil with a fresh batch.
Tiny
generatorshovel #52
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:12/06/2008 11:46 AMCopy HTML

More progress,,,still sorting the tuning out,,,,carb No3 is on, numerous jet changes today.
She is running HEAPS better now, although idle is a word it doesnt understand yet, unless it involves 2,000 revs, I'll try backing of the ign advance tomorrow.
It sure roars when the throttle is blipped, or opened quickly@ the lack of flywheel effect sure makes itself known (it may also have a lot to do with its hate of low revs), the slightest blip of the throttle sees the tach launch itself to 6,000 rpm.
By this time tomorrow I will have done all I can to sort it out untill I take it on its 1st run out on a secluded road and do a few flog n chop runs, and no doubt, jet and timing changes.
Flyby video will be posted when it becomes available.
Tiny
brucifer #53
  • Rank:Platinum Member
  • Posts:327
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:12/06/2008 2:49 PMCopy HTML

Good job Tiny! Lookin' forward to seeing the vid.
generatorshovel #54
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:12/31/2008 9:44 PMCopy HTML

Sorry 'bout the delay , the test ride fially happened 2 days before christmas day,
http://s156.photobucket.com/albums/t24/generatorshovel/?action=view&current=Hypos1strun.flv
Enjoy !
Tiny
Motoracer838 #55
  • Rank:Gold Member
  • Posts:121
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:01/02/2009 1:48 AMCopy HTML

Tiny, that thing sounds absolutly EVIL. I need to know when your going to salt flats.

Cheers Beers n Gearz. Joe
generatorshovel #56
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:01/02/2009 7:57 AMCopy HTML

That is the million dollar question Joe,,,the link will help to explain.
http://www.dlra.org.au/
Tiny
Franklin_Speedy #57
  • Rank:Bronze Member
  • Posts:39
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:02/08/2009 10:53 PMCopy HTML

as i read this, i kinda have a thing to ask, I sent an email to powroll asking on what i should do for my cafe racer.
the bottome end i have right now is 1974 cb125s 49.5mm stroke. and i have a xr200 cylinder with is 65.5mm kinda like what generatorshovel is using.
thats what 166cc. I was wanting to know could that run ok on the street. if i cant get a way with running a stroker of 59.4mm with a 66mm piston to get 203cc. or a 67mm piston to get 209cc . then i may be just wasting my time on my engine build. I'll be using a xr200 2valve head. on my cb125 cases with a sl125 transmission.
my goals are to build a wicked little cafe road racer to ride on the street ripping up the back roads by my house.

any ideas or inputs on that i should know, or do.

generatorshovel #58
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:02/09/2009 8:54 AMCopy HTML

Speedy,,,,depending on how fast you would like to go, and the effort you would require to do it,,remembering outright power is best achieved with a hi revving engine, but the drawback with that is it would not be much run to ride other than flat out on the boil.
The other way is a stroker,,lazy power, on tap, at low to moderate revs, easy to go quickly at a blip of the throttle.
One of your plans (stroker) seems a difficult way of almost duplicating what Honda has allready made,,the XR200,,,basically a stroked 125, big bore, with a few beefed up parts thrown in ?
Remember, no matter which way you go,,you can only tune to put your power band somewhere from 3.000 ,,to (gulp) 12,000, but NEVER from 3000 to 12000 inclusive, you can't have your cake, and eat it too, unless you settle for a small cake,,that takes a long while to eat, personally,,I'd rather scoff it down in one gulp,,lol
Have you considered working a 200,,or even a 200 top on a 175 (easilly done)
Tiny
PS, the engine numbers section of the crankcases on both engines, could be coaxed into either engines, so you could be excused for forgetting which bottom end was what
Franklin_Speedy #59
  • Rank:Bronze Member
  • Posts:39
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:02/09/2009 4:11 PMCopy HTML

My normal riding sytle on my more modern sportbikes is rev it high and let it scream unless im in traffic of course.
on my little honda my goals are to ride it like a isle of man tt racer on the back roads where i live, so pushing 8 - 12K  would be my area im looking to make my peak power. low end is not a bother to me, i love the sound of a high reving engine and I love to build something diffrent. My thing is i want to show off the engine case that has CB125SE stamped on it. when the kids at the local bike nights take alook at my machine and wounder how I can make it scream and run the way i would.

MY bike is a 1974 CB125S that i have turned into a cafe style racer, I even went with alum rims, stainless spokes Ti nipples, I even went and had a friend custom make me an alum gas tank, anything to make my bike lighter. I have drilled a ton of speed holes into the rear brake drum cover, the sproket cover, I have trimmed every bit of fat off the fat that i wouldnt need to make it road legal,  My goal is to get well into 75 mph or maybe hit the ton (100 mph) just once on the speedway near my home. I have a SL125 trans mission witch has a 2.77 first gear and a .8 5th gear. so all i really needs is the power to pull top gear at above 6K rpms. for miles at a time with out blowing up. lol.  I have a bunch of sprockets to choose from to get my final gearing to where i like it.

I may even do half the stroke that powroll offers and build me a 185cc with 54.25mm of stroke. but im shooting just for a high revving screamer that will be able to do it with out major problems. IM not looking for all out HP but want to push near the limits of what it can make, i know HP is what makes you go fast. TQ gets you going fast. if i want to break tripple diggits ill ride my 2005 suzuki GSXR750. but i want to build my bike as a tinker toy to ride and tune and play with. and put about 20 - 30 miles on it on a weekend. right now its wbour building the engine later would be the fun of tuning it and adjusting to make it run better and better till theres no more to do other then tear it all back down then go bigger and stronger.

O and tiny your the burt munro of today,  like they say once you get a taste for the salt you will go back every year till you cant do it no more, I have that same problem with having the pocono raceway where i live, every year i do track days on my 05 suzuki gsxr750 and every year i tune to go faster lap times. im 28 yrs old and i have been riding motorcycles since i was 5yrs old its in my blood,
Franklin_Speedy #60
  • Rank:Bronze Member
  • Posts:39
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:02/22/2009 2:34 PMCopy HTML

have you been to the salt here in the states, at bonneville salt flats.



Go soothingly on the grease mud ... as there lies the skid demon! ...





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