Actually if you go back to my 2nd set of pictures... You will see the Yamaha Y80 Belle. It looks worse then it really was (only 36,200 Km on it). When I desided to use (Try) to motor, 1st because it was Semi Automtic. Meaning I could still use both hand brakes. 2nd because it ws cheap (I already had it! and alot of the parts I would end up using also)
The only things I did to motor to insure reliability after all this work I didn't want to end up with junk! Remember, I am in Thailand and the Baht which it the currency here has been around 31.50 - 29.87 to One USD ($1.00) yes! Blessing!!
I spent 70 Baht new Crankcase seals, 150 Baht New Cylinder, 230 Baht new piston and rings set 15 baht complete gasket set (Complete) 50 Baht Carburator rebuild/gasket kit.
Took me 4 hrs to completely overhaul Engine, including scrubbing down outside of it completely. I changed crankcase oil 650cc, bought a bottle of 2T oil (From Shell Oil!! Yes they are here also..) I cut the Headtube off the Yamaha to use for 2 reasons. First it would fit any fork I chose to use. Further in case I wa going to have issues with Ministery of Transportation it also had Matching Serial number with engine stamped on it!! Just to show in case I needed that the part were indeed from the Belle I had Title for (here they cll it a Green Book)
I also desided to replace the reeds, they were plastic (fiberglass) and bent a little from sitting. The new were stainless. The cage was Aluminum so I polished inside it and throat of crankcase to where piston was. Intake to carb and throat of Carb this took me two days. I also did Exhaust Port opening it as much as I could. By this time I ws wishing it had Electric start...nope! not that lucky, wasn't even available!! I looked!!
I also used the body section that included the Engine mounting holes This was going to make hanging it easy, as I was the only one interested in what was happening in my Garage! haha! As long as I wasn't spending alot of money my wife was happy!! and stayed away, I knew if I asked her to help me and push the bolts through the mounts she was going to start asking questions!... haha!
I took the original Yamaha seat and removed cover and foam. Cut out 12" in length and put back together. Used a heat gun to form the shape I wanted (to look like a Sportster 2-up seat) ended a little shorter I actually took athe cut away section and cut it in 1 1/2" strips and melted it over to custom base I hd made. filling voids and thickening where it looked it need it. I added 6 bolts to base to in rear to fasten to frame and 2 in nose to fasten to metal strip that slides under rear of petrol tank. using the two seat spring from the bicycle I fastened them to the last two bolts. Then I took the foam and original cover and mess I thought (My wife thought I had made) I had to a MotorCycle/Bike shop and as I walked it he pointed around the corner and smiled. He knew what I was doing and had been at the house several times to drink a beer (Singha) and help when he could. His shop was a Harley Chopper area. He kept telling me that if it looked good... it was going to ruin his Business! then he'd say nuther beer... and smile!
To get seat finished... cost me 150 Baht! (they wanted 250 USD for the smallest Harley Sportster 2 up seat and it was used, also!) Wow!
I used two Murry Steel Ladies bikes to build my frame, or at least to get the basic look I wanted. the cross bar actually fit perfectly inside the down tube so I took one frame and cut it off at seat post and BB. turned it over and layed it down. The other frame I cut the Headtube off and top tube off at seat post also. Cut off the top fender fork and took out 14" from seat tube. This was going to be the height of frame from original BB.I hd alread found some tubing that fit inside the top tube and had cut it to the length I wanted to stretch the frame to.now laying what I had left of this frame to the right of the first one, with the sections I had cut for length I slide everything together (rubber mallot help here alot as it was also 2130 hrs
. with frames on concrete floor I ws able to keep frame aligned. I needed to bend top tube up to top of seatpost position. Using my feet to push little at a time and then stand on frame to realign it at times. I ended up heating tube at headpost to get it in a nice bend. wasn't worried about crimping headtube as I was going to use the Yamaha's. I use a front fork to position where I wanted BB for pedals and then remove from discarded section of 1st frame used about 10" of seat post attached and spot welded everything in place turning frame over a couple of times to insure straight.
So guys that how the Bike became a Chopper (The Belle had grown up!!) haha!
Basicly tools I used were normal to strip bike and motorcycle. I reused what I had left of harness until I found a complete one (which I just got) I used 4 - 4" cutting wheels in my hand grinder. Propane torch to heat tubing and frozen parts, and small portable welder. I had taken my propane torch head (no tanks!) from America to here. we have gas cylinders for small one burner stoves that are same size and work quite well. I have since smuggled 3-4 more torch heads of different sizes here in my luggage. I don't think they cared as it was just a piece of brass and ws NOT in my carry on... The worst I ever had was on the way to Airport in Seattle I stopped at Pepboys and bought two sizes of spark-plug Sockets. then as I left put them in my coat pocket. When I emptied everything at scanner you would have thought I was planning to dismantle the Aircraft (I didn't even have a ratchet, for Gods sake!) So I openned my suitcase and dropped them in... saying they were being checked... 4 of the guards laughed and he Just turned away... I think he needed them at home!! haha
Most of the pictures need to be resized so I can post. I even have a set showing how to add the freewheels to the pinless axle (square headed) in original BB to transfer power from left side of bike to right. No copyright infringment here as it the original BB
Legal.. YES! must have:
Power under 100cc - (Bore and stroke it, theyre not going to cc it!)
lights I have all that a Motorcycle has, even turn
mirror, I have 2
sound device I have 12V horn
I am an Adult (Over age 15)
It has working pedals
Must wear Helmet.. As Name on Tank says... "Thai One On...!"
When all above is used. Bike is legal for street use. No License, personal or for vehicle is needed.
There are a few of the original with tube tanks hung under cross bar and chinese motors. But here in Chiang Mai The Government said it was a first! My wifes uncle was Vice Governor in Lampang Province and he collects old bikes has about 40, restores. This was how it got presented as a project also to enhance recyclability and a way to give a 2nd vehicle to those who could not afford. Everyone has at least One Bicycle and maybe a Motorcycle too. Not always a car. Get the usability??? Dad take Motorcycle to work, Mom takes kids to school on Bike sometimes three on a bike, or even 4 on a motorcycle... Adding a Motor saves moms legs!
To oil chains I have a plastic oil bottle with side cut out and a mix of grease and oil/petrol and small paint brush. with motor in neutral... pedal and tip bike so rear wheel is off ground easy to do all three chains in two minutes!
(I used all 428 M/C chains and sprockets, the 2nd set of sprockets on chainwheel/crank and center location is what gives you the ease of using pedals to overcome any weight. Weight lets bike ride smoothly even for a "Hardtail".)