How to Booklet

deacon · #1 (**permalink**) 08-13-2008, 09:29 AM

Some of you know that it has been my plan all along to write a, "How to build a motorbike from scratch for dummies" booklet. Well it's raining today so I started it.

I am always looking for advice so let me run this by you.

I am going with the idea that all parts have to be available at the Home Depot. No welding since the average guy can't weld. Everything has to be pretty much off the shelf with simple modifications, using simple hand tools which most people have. I know that is hard for most people here to grasp, since most of you have better skills than my booklet will call for.

The build itself with concentrate on:
Bicycle modifications to accept the engine.
Engine preparations.
Building the engine mount.
Mounting the engine and controls.
and a lot of warnings about the use of motorized bikes.

So what else does it need.
Oh yeah lots and lots of pictures

jasonh · #2 (**permalink**) 08-13-2008, 10:04 AM

I would definitely add a section on maintenance. Maintenance is important.

deacon · #3 (**permalink**) 08-13-2008, 11:04 AM

Yes I am going to do that in the operators info section. Mostly though its just mix the gas, Check the nuts for tight once a week or so, empty the gas out if you don't plan to ride it over the winter. Run the carb dry, that kind of thing. I chose the weed whacker so that they could carry it to the small engine shop for any real engine work.

For filling and emptying the gas tank I'm going with buy yourself a turkey baster.

gasequoia · #4 (**permalink**) 08-13-2008, 11:35 AM

Am instrested in the book--just finished reading all 15 on Nam--Help me out here-- Bought a kit {80cc} China from boysgofast and cannot get to fire. Am getting fire and fuel-- Lots of compression--Hasn't hit first time

deacon · #5 (**permalink**) 08-13-2008, 12:36 PM

I have that kit. I'm not really qualified to help but there are a couple of things that can be happening.

most likely is an air leak in the intake manifold. If you have checked that the magneto key may be loose causing it to spark before the compression is right. There are plenty of other things but I'm not that good at these things. Not even trying to start makes me wonder about the clutch as well. Some of the guys had it slipping to the point that the engine wasn't turning fast enough.

Some of the others here are a lot more qualified than me. Try norman or bike guy joe, they can give you much better advice.

The truly wise man knows when to pass the ball.

Radmanfly · #6 (**permalink**) 08-14-2008, 09:24 AM

a contribution to your book:

Guide to Roller Chain

There were many different manufacturers of minibikes back in the 60's and 70's but most of them used one of three different size roller chain. You may see chain size referred by what pitch is has. The pitch is simply the distance from pin center to pin center. If you need new chain and your having difficulty determining the correct size that you need. Here's some information that may be helpful.

Number 35 Chain: Pitch = 3/8" | Roller diameter = 3/16" | Roller width = 3/16" | Pin diameter = 1/8" | Tensile = 2,100

Number 41 Chain: Pitch = 1/2" | Roller diameter = 5/16" | Roller width = 1/4" | Pin diameter = 1/8" | Tensile = 2,000

Number 40 Chain: Pitch = 1/2" | Roller diameter = 5/16" | Roller width = 5/16" | Pin diameter = 5/32" | Tensile = 3,700

Number 35 was uses on most all 4-5-6 inch wheel minibikes while 41 was used on larger minicycles such as Rupp Roadster II and Speedway. Number 41 chain will not run on a number 40 sprocket. Number 40 chain will run on a number 41 sprocket but it will be wider than needed. (Like many china bikes!)

SPACE CHAIN

Space chain is handy if you have sprockets that don't align properly. On space chain the outer links are just a bit wider so there is a small space between the inner and outer links. This space allows the chain to flex side to side much more than standard roller chain and will not run off the sprockets as easily. Although space chain is available in most sizes it is usually not a stock item and may be a special order.

deacon · #7 (**permalink**) 08-14-2008, 10:48 AM

Thanks but the booklet is just about how to add a weed whacker friction drive to the front wheel. Not an all purpose motor bike how to. I am far from qualified to do that. Some of the other guys should though.