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Bike Build as of March 2012

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Bike Build as of March 2012

Post by Fabian on Sun Mar 11 2012, 06:44

This video (link at bottom of page) is a walk-about of my motorized bike build and after 2 years of trials and modifications, the bike has finally given a usable level of reliability and functionality under the most severe riding conditions.

The digital gauges in order from top left to right and middle and bottom are: Tacho, speedo, Koso exhaust gas temperature gauge and TTO cylinder head temperature gauge.

The only things missing are an electronic fuel gauge, electric start, generator and electronic fuel injection, but i'm working on it.

List of improvements so far and in order of reliability modifications.

1) Mudguards.

2) Bicycle engine.

3) Modified center stand.

4) Sick Bike Parts Shift-Kit  Laughing
http://www.sickbikeparts.com/catalog/product_info.php?cPath=21&products_id=29&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

5) Sick Bike Parts air filter.
http://www.sickbikeparts.com/catalog/product_info.php?cPath=22&products_id=40&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

6) Sick Bike Parts spark plug lead.
http://www.sickbikeparts.com/catalog/product_info.php?cPath=22&products_id=39&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

7) Sick Bike Parts fuel tap.
http://www.sickbikeparts.com/catalog/product_info.php?cPath=22&products_id=50&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

8) Sick Bike Parts optional sprockets.
9 tooth - http://www.sickbikeparts.com/catalog/product_info.php?cPath=21&products_id=31&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

11 tooth - http://www.sickbikeparts.com/catalog/product_info.php?cPath=21&products_id=30&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

24 tooth - http://www.sickbikeparts.com/catalog/product_info.php?cPath=21&products_id=65&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

30 tooth - http://www.sickbikeparts.com/catalog/product_info.php?cPath=21&products_id=66&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

36 tooth - http://www.sickbikeparts.com/catalog/product_info.php?cPath=21&products_id=36&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

48 tooth - http://www.sickbikeparts.com/catalog/product_info.php?cPath=21&products_id=67&osCsid=oh31d9ma3pedlaoi3e7l24nfd4

9) Silicon exhaust deflector - significantly reduces exhaust noise.

10) Gel pad (wide) comfort seat.

11) Thorn proof inner tubes - these things really work!

12) SRAM X9, 9 Speed Grip shift fitted to left hand side of handle bars - trigger shift went straight in the rubbish bin.

13) Sram X9 rear derailleur.

14) Right hand side chain tensioner.
http://motorizedbikeforum.the-talk.net/t133-chain-tensioner-for-chainwheel-side-of-sickbikeparts-sick-bike-parts-sbp-shift-kit

15) Cane Creek Thud Buster (long travel) suspension seat post.
http://www.thudbuster.com/products.html

16) Left hand side chain tensioner.
http://motorizedbikeforum.the-talk.net/t128-chain-tensioner-for-2-stroke-engine-and-sickbikeparts-sbp-sick-bikeparts-shift-kit.

17) Tacho by means of using a bicycle speedo on the Sick Bike Parts Shift Kit.
http://motorizedbikeforum.the-talk.net/t134-super-simple-bicycle-tacho

18) Long range fuel tanks attached to bicycle seat - giving the opportunity to run out of fuel 3 times instead of just once   Very Happy

19) Accessory lights.

20) Brake light.

21) Rock Solid Engines billet intake tube.
http://shop.rocksolidengines.com.au/index.php?page=shop.product_details&flypage=flypage.tpl&product_id=93&category_id=15&option=com_virtuemart&Itemid=1

22) Dellorto Number 70 main jet for an SHA style Dellorto carburettor.

23.1 Tetra Chainwheel Modification, using Sick Bike Parts optional 24 tooth and 30 tooth sprockets, used in a gear stack with the original 36 tooth sprocket for final drive to the rear cassette, combined with (and on the same gear stack)  the Sick Bike Parts optional 48 tooth sprocket for the secondary chain drive from jack shaft.

http://motorizedbikeforum.the-talk.net/t132-tetra-chainwheel-system-for-sickbikeparts-sick-bike-parts-sbp-shift-kit

http://motorizedbikeforum.the-talk.net/t137-video-tetra-chainwheel-operation-sickbikeparts-sick-bike-parts-sbp

23.2 ) Modified front derailleur working with a triple gear stack using Sick Bike Parts 24 tooth, 30 tooth and 36 tooth  sprockets.

24) Front derailleur shift lever fitted to left hand side of handle bars.

25) Roller clutch routing modification.
http://motorizedbikeforum.the-talk.net/t131-modified-clutch-cable-routing-for-2-stroke-engine

26) Chain seperators.

27) Winkku left and right hand (combined) mirrors and indicators - make sure you purchase a few spare "Pro Bracket" handlebar attachments for these break on impact (or if you hit something solid, like a slow moving pedestrian), preventing damage to the mirror in the event of the bike crashing on it's side - please take my advise as the brackets are only $5 each.

http://www.bb-shopping.com/products/Pro-bracket.htm?id=64&subid=&prodid=6167&curr=&m=1.00&cc=2

and the mirrors are here


http://www.bb-shopping.com/products/Winkku-Bicycle-Lights-Mirror-&-Indicators.htm?id=64&subid=&prodid=5488


28) Airzound bike horn (recommended manufacturers pressure) 80 psi - i run the bottle at 140 psi and it's LOUD

29) Hayes 9" V9 disk rotor and modified Hayes brake caliper adapter to work on an I.S. mount.
http://motorizedbikeforum.the-talk.net/t195-hayes-9-adapter-on-an-is-mount

30) Modified Shimano 29'er cassette to give a custom sprocket stack: 36 - 28 - 23 - 19 - 16 - 14 - 13 - 12 - 11

31) Dual idler rollers and captive stays for final drive.

32) Circular (see through) chain guard for Sick Bike Parts Shift-Kit.

33) Final drive Chain Stabilisation Device.
http://motorizedbikeforum.the-talk.net/t194-chain-stabilisation-device-in-conjunction-with-sickbikeparts-sbp-sick-bike-parts-shift-kit

34) TTO Cylinder head temperature gauge.
http://www.jnmotorsbikes.com/product_p/jnm1183.htm

35) Modified centrifugal clutch.
Place of Purchase - http://www.jnmotorsbikes.com/product_p/jnm1166.htm

Standard C/Clutch - http://motorizedbikeforum.the-talk.net/t193-centrifugal-clutch-48cc-60cc-66cc-80cc-pull-start-pedal-start-2-stroke

Modified C/Clutch - http://motorizedbikeforum.the-talk.net/t196-lubrication-port-modified-centrifugal-clutch-48cc-60cc-66cc-80cc-pull-start-pedal-start-2-stroke

36) Jaguar CDI and coil.
http://www.jnmotorsbikes.com/product_p/jnm1195.htm

37) Modified pull-start.
Place of Purchase - http://www.jnmotorsbikes.com/product_p/jnm1170.htm

Modified Pull Start - http://motorizedbikeforum.the-talk.net/t198-pull-start-pullstart-pull-start-80cc-70cc-66cc-60cc-48cc

38) Koso (fast response) exhaust gas temperature gauge and (1.3 amp/hour) 12 volt sealed lead acid battery (not included with EGT Gauge).
http://www.exhaustgas.com/ProductDetail.asp?ProductID=1482&DepartmentID=10&CategoryID=71&RepID=&BasketID=










39) Rock Solid Engines Billet Reed Valve Kit
http://shop.rocksolidengines.com.au/index.php?page=shop.product_details&flypage=flypage.tpl&product_id=286&category_id=15&option=com_virtuemart&Itemid=

http://motorizedbikeforum.the-talk.net/t209-rock-solid-engines-reed-valve-installation



40) 1400 Lumen CREE LED XP-E 16W SSC P7 Rechargeable Bike Bicycle Light
http://www.batterymax.com.au/products/1400-Lumen-CREE-LED-XP%252dE-16W-SSC-P7-Rechargeable-Bike-Bicycle-Light-.html

MTE 3M-2I XM-L 1000 Lumen CREE LED Flashlight Bike Light Rechargeable set
http://www.batterymax.com.au/products/MTE-3M%252d2I-XM%252dL-1000-Lumen-CREE-LED-Flashlight-Bike-Light-Rechargeable-set.html

The brightness of the 1000 lumen rechargeable torch was astonishing; certainly beyond my wildest expectations for something so small; being attachable to a bicycle made it even better.
The 1400 lumen dedicated bicycle light was equally impressive, with a more diffuse spread, yet still blazingly strong illumination.
Combining both lights on the bike gives 2400 blinding lumen's; virtually equaling the intensity of car headlights on high beam and compared to what i've been used to, it's been a jump from the stone age to the space age in one single step.

41) Wonderful Creations 12 Volt Lighting System.
Although this (wonderful) accessory won't be fitted in March, it should arrive in April; to be installed shortly thereafter.
The idea of having a generator suppling regulated 14.4 volts to the battery is appealing and really opens up the concept of installing an electronic fuel injection system.
As things stand, i'll be replacing the halogen globes with high output LED's to compliment the new lights fitted to my bike.
I'm aiming for a combined total of 4,000 lumen's on high beam - a figure high enough to scramble the navigation computers on incoming UFO's  Very Happy

http://www.ebay.com.au/itm/Complete-12-Volt-Lighting-System-Motorized-Bicycles-/400108735081?pt=LH_DefaultDomain_0&hash=item5d2856ca69#ht_4553wt_752


42) Minoura Accessory Holders
Camera Mount -  http://www.minourausa.com/english/accessory-e/vc100-e.html

Adjustable Height Water Bottle Holder -  http://www.minourausa.com/english/accessory-e/ab1600-e.html

Adjustable Accessory Holder -  http://www.minourausa.com/english/accessory-e/sg200-e.html

Suspension Fork Accessory Holder -  http://www.minourausa.com/english/accessory-e/lh50-e.html

Snap Lock Accessory Holder, 22 to 29mm -  http://www.minourausa.com/english/accessory-e/sg300s-e.html

Snap Lock Accessory Holder, 28 to 35mm -  http://www.minourausa.com/english/accessory-e/sg300m-e.html

Smart Phone Holder -  http://www.minourausa.com/english/accessory-e/ih100-e.html





*  For those who may need a solution for "serious" cargo carrying capacity, the following photos and accompanying video may provide a usable option for your heavy haulage requirements.

http://motorizedbikeforum.the-talk.net/t135-multi-combination-bicycle-trailer-setup-bike



My current general day to day runabout is a BoB IBEX 28 suspension trailer:

1)  http://motorizedbikeforum.the-talk.net/t206-bicycle-trailer#329

2)  http://motorizedbikeforum.the-talk.net/t208-bob-ibex-trailer#331




Video link:  http://www.youtube.com/watch?v=UicCKo0Qf0Q
If you would like any extra info about the bike or reliability improvements, my email is:  yldflight@hotmail.com




Last edited by Fabian on Wed Jun 12 2013, 10:17; edited 2 times in total

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Re: Bike Build as of March 2012

Post by skinnywheelz on Sat May 05 2012, 20:21

That is awesome. You are one serious Gear-head my friend.
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Re: Bike Build as of March 2012

Post by Fabian on Sun May 06 2012, 01:43

Thanks Skinnywheelz

Now that the reliability issues have been sorted out with a bunch of engineering improvements, my motorised bicycle is a joy to use; allowing long distance touring to some picturesque places; sometimes inaccessible by 4WD or motorbike, with the road surface barely resembling goat tracks in past travels.

Hope some of my modifications might be of use to improve reliability or make your motorised bicycle more user friendly.

Fabian




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Re: Bike Build as of March 2012

Post by RedRider48 on Mon Dec 02 2013, 20:53

Hi Fabian,


This list will take a month of Sundays to go through, for which, I'm mighty appreciative. Thanks abunch!

Ken

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Re: Bike Build as of March 2012

Post by RedRider48 on Tue Dec 03 2013, 08:14

Fabian,
Two questions....
1. What make and model engine and from whom did you purchase?
2. I can see you're running a triple crank gear and a 9 speed cassette, how is the shifting? That is, any issues? I was thinking of running a similar multi-speed, 3 Spd. crank and 7 gear cassette.
Thanks,
Ken

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Re: Bike Build as of March 2012

Post by Fabian on Tue Dec 03 2013, 09:28

The engine capacity is 69cc and it was purchased through Powercycle in Bayswater (Melbourne).

The triple front gear stack works acceptably but the centre to centre spacing is very compact (due to packaging constraints between the 36T sprocket and the bicycle frame); making it more compact than the Shimano SIS indexing likes it to be. It does shift reasonably as you can see by the video but you need to plan your shift ahead of time.

To be honest the triple arrangement gives no real advantage over a double setup because there is only a 6 tooth difference between chain rings.

From my personal experience, i never use the middle 30T sprocket and jump directly from the 36T sprocket straight to the 24T sprocket when the going requires low range gears.

When my front sprockets need replacing i will be deleting the triple setup and going to a double setup, which allows me to correctly space the centre to centre sprocket distance in sync with the older SIS thumb shifter; to give fast and positive chain derailment to the 24T sprocket.

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Re: Bike Build as of March 2012

Post by RedRider48 on Tue Dec 03 2013, 10:02

Thanks for reply. So, you're an Aussie mate eh? I have a couple of mates, with whom, I correspond. One in Pittsworth and the other in Williamstown.
Where be you residing, if you don';t mind me asking?

Ken

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Re: Bike Build as of March 2012

Post by Fabian on Tue Dec 03 2013, 17:27

I am located in the south eastern suburbs - Ringwood area.

An Aussie i am - i even took along a jar of Vegemite on my last trip to Thailand.

Fabian

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Re: Bike Build as of March 2012

Post by RedRider48 on Tue Dec 03 2013, 19:34

Fabian wrote:I am located in the south eastern suburbs - Ringwood area.

An Aussie i am - i even took along a jar of Vegemite on my last trip to Thailand.

Fabian
Ringwood, eh mate! I'll have to pin you on my Aussie map! Vegemite? I've learned a lot of Aussie lingo, but not, that one yet.
Ride on brother, ride on.....

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Re: Bike Build as of March 2012

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