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Project CT/XL trials bike

Discussion in 'Other Projects - Other Bikes (non 250's)' started by Murdo, Feb 25, 2018.

  1. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Was given a Honda CT200 rolling frame a while ago, and I just happen to have an XL185 engine with XR200 barrel on it, and will make these bits (and a few new bits too) into a trials bike something similar to a TLR200 like this one.
    Trial bike 002.jpg
    This is all I have of the CT, so no point in trying to restore it.
    Trial bike 001.jpg
    It will end up a bit heavier and wider than a real TLR, but should do me ok.
     
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  2. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    I started on stripping the engine. It had been used in a kids go-kart until it seized, and was then left out in the rain.
    Cam chain was falling off the sprocket, not looking good.
    CTXL 001.jpg
    After a lot of struggling I got the piston out of the bore, looking less good.
    CTXL 002.jpg
    With the cases apart it wasn't too bad inside. The crank bearings are gone from sitting in water, but the rest of the gearbox will be useable with a good clean up and new gaskets/seals.
    CTXL 005.jpg
    There is a big piece missing from the case from a thrown chain that will have to be welded back in.
    CTXL 011.jpg
     
  3. Andych

    Andych Well-Known Member Premium Member Contributing Member

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    Looks to be a good little project.. As you say.. it will be a touch heavier but then the 185 / 200 was nice and torquey so it should be a lot of fun when finished..
    I had heaps of fun on Trials bikes when younger and lighter.. it is amazing to watch the top trials riders and what they can do on their machines...
     
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  4. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Got a bit of welding to the cases done. I welded an extra piece of 6mm plate so as to be able to tap a thread and it fits up to the sprocket cover nicely.
    VJMC rally 2018 002.jpg
    The new rims and spokes arrived, so I blasted and painted the hubs satin black and put them together. Looking 'spiffy'.
    VJMC rally 2018 018.jpg
     
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  5. Andych

    Andych Well-Known Member Premium Member Contributing Member

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    Those wheels look really slick. This is going to be another stunner from @Murdo


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  6. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    So what did you get the radial and lateral runout down to?

    Ps... guess who did spokes and rims at tafe last week :thumb_ups:
     
  7. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Pretty much spot on for radial and about 1mm lateral. It is a slow dirt bike so a slight wobble wont worry it (and most dirt tyres are not that straight), and will probably get dinged anyway.
     
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  8. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    With the tyres fitted I mounted the frame up on the jig to do some measuring. With the frame mods I've done the forks came out at almost spot on at 26 deg with 90mm trail (TLR is 26.5 at 86mm) with wheel base only 35mm longer.
    MC-14 001.jpg MC-14 002.jpg
     
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  9. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Have the engine completed now and fitted and made the missing mounting plates. Had to do some welding of the exhaust to get it aligned and sealed.
    ctxl 004.jpg
    Had to make the rear brake pedal. Used a broken piece from the 'spares' box which has a folding tip and then had to make the rest. I started with some 30x3mm flat bar and bent it over a 10mm plate, drilled an 18mm hole and heated red hot and drove the splined shaft through to make the female splines. A clean up with a file and fitted nicely. Welded to the brake arm and some grinding to clean up ready for paint.
    ctxl 006.jpg ctxl 005.jpg
    I made the brake rod from a piece of 6mm bar. Bent at 90 degrees on one end and threaded the other. Drilled holes for split pins.
    I found a rear sprocket of the right size (and the right price :thumb_ups:) that has hardly been used, but with too big a centre hole. I bought a piece of 100x8mm flat bar 100mm long, drilled a 22mm hole in the centre and fitted a big bolt and nut to allow it to be held in the lathe. I cut the outside down to the inner size of the sprocket, took the bolt out and held by the outside in the jaws and bored the centre hole to fit the Honda hub. Will drill for the 4 mounting bolts and then weld the two bits together.
    ctxl 003.jpg
     
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  10. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Got the frame stripped down and off to sandblaster. Welded, drilled and fitted rear sprocket to hub. Visit to paint shop tomorrow.
     
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  11. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Threw a bit of paint at it last Friday before I went away for the weekend.
    CTXL 002.jpg
    Most of it stuck.
     
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  12. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Painted some bits black and when dry fitted to frame.
    CTXL 014.jpg
    CTXL 013.jpg
    Even the brake lever I made turned out alright.
    CTXL 015.jpg
     
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  13. Andych

    Andych Well-Known Member Premium Member Contributing Member

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    Looks pretty slick @Murdo
    Won’t be long and you will be powering up rocks and logs


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  14. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Made the brackets and fitted up the guards today.
    Thinking about the wiring of the headlight and tail light, will LEDs run on AC (ie direct from the magneto) or do I need a battery/rectifier etc to run them?
     
  15. Andych

    Andych Well-Known Member Premium Member Contributing Member

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    Hmmm I would think that LED's need a constant supply.. but then I believe that electricity is "white mans magic".
     
  16. Wozza

    Wozza Active Member Premium Member Contributing Member

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  17. ruckusman

    ruckusman Well-Known Member Premium Member Dirty Wheel Club

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    Another Murdo Epic Creation I see - great work

    Led brightness control is achieved by pulse width modulation, basically high frequency switching to increase/decrease output. It's a version of AC, high frequency which doesn't have a zero crossing point so never goes negative.

    An led will run from AC - being a diode it blocks the reverse voltage on change of phase.

    However the lifespan could be brief and the voltage direct from a magneto would be potentially quite high at high revs I would have thought.

    Been decades since I dealt with a battery less electrical system - Two or three wires out of the magneto?
     
  18. my67xr

    my67xr Well-Known Member Premium Member Contributing Member

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    I'm pretty sure you could use a full wave reg/rect, they are easy to wire up and are pretty cheap
    https://www.ebay.com.au/itm/12V-4-p...721642?hash=item3cc527402a:g:F~sAAMXQudxRYj60
    This would supply the dc voltage to your headlight switch and also the brake light switch's

    s-l500.jpg
    Rect.gif


    Or if your lighting system is regulated by the headlight you just use 2x full wave rectifier's, one for the stop and one for the tail, have the earth and battery wire's run from one rectifer to your stop light, and the battery wire's from the 2nd rectifier to the tail light.
    These are pretty small, 2x rectifier's are a touch longer than a matchbox but not as thick, the voltage/amp rating's on them are overkill
    Run one yellow from stator to the yellow, then the second yellow from stator to the pink
    https://www.jaycar.com.au/po4-6a-400v-bridge-rectifier/p/ZR1314

    icon-bridge-full-wave-rectifier-testing-home-of-the-pardue-of-rectifier-regulator-wiring-diagram.jpg
     
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  19. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Thanks guys, that is exactly what I wanted to know. Been a long time since I did similar to bikes in the 1970's.
     
  20. my67xr

    my67xr Well-Known Member Premium Member Contributing Member

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