This makes it very difficult to bleed the brakes but worst of all it is down right dangerous!
I was recently tasked with reconditioning a Honda CB-500 Four that had been left in the weather for a few years. When I saw the bike one of the first things that I noticed was the “front brake reservoir delete” or in simple terms a piece of Tygon tubing with a plug in it. I wasn’t impressed but had seen something similar plenty of times on the motorbike blogs and on race bikes.
Then when I went to bleed the front brake I had one squeeze of the lever (with the bleed nipple open) and then nothing. No brakes. No pumping. Nothing and the tube was still full of fluid. Continue reading Please Don’t Ever Do This!
As mentioned previously on this blog, this is a motard style conversion of a Honda CRM 250 using a 2007 model Aprilia RS-125 wheels, discs and front brake caliper.
A custom bracket was designed in Solidworks to adapt the radially mounted caliper to the original brake caliper mounting holes. Designing in 3D allowed the part to be simulated (FEA) with heavy braking loads and calculate the factor of safety, stress, strain and distortion.
One of the advantages of using the Aprilia wheels over the popular wire spoke wheels is that they incorporate a cush-drive to reduce driveline vibrations. Continue reading Motard Complete & Tested
A recent project was figuring out how to adapting a YZ-125 motorbike engine to a go-kart frame.
A kart usually has two parallel tubes to mount an engine to sometimes a flat plate that is welded into the frame. A motorbike on the other hand has a frame that encircles the engine or even uses the engine as a stressed member forming part of the chassis. The kart for this engine had a flat steel plate with a few slotted holes to bolt the engine in place and was situated behind the axle close to the centerline. Continue reading Adapting a Motorcycle Engine to a Go-Kart
The calipers have been dis-assembled and inspected. The castings of the inner and outer caliper halves are symmetrical, front to rear, and could be machined to suit either the left or right hand side fork of the motorbike.
Now onto the inspection…
Continue reading Aprilia RS-125 Calipers
Some good news, a delivery arrived with the fasteners needed for the sprocket and brake bracket. Nice black finish high-tensile metric capscrews and countersunk socket screws.
Continue reading Motard Update – Aug 2015
Recently turned a few spacers on the lathe for the CRM to motard conversion (see earlier posts – CRM 250 with Aprilia RS-125 wheels & brakes).
Continue reading A Little Bit of Turning
The fabrication of the motard bracket, to adapt the Aprilia RS-125 radial mounted caliper to the Honda CRM-250 front forks, is now complete and the results are quite pleasing.
Continue reading Finished Fabrication of Motard Bracket
Here is a drawing of the basic Motard Bracket.
I hope to make this using a manual mill, drill press and hand-tools when time permits.
Following on from the earlier post I have carried out further refinement with FEA of the Motard brake bracket.
The first design was somewhat simplified to provide mounting of the Aprilia brake caliper to the CRM 250 without too complex a shape so that it could be produced using a manually operated mill and some hand tools to fabricate. Looking at the results from the simulation showed one area that required improvement, between the upper caliper mounting bolt and the upper bracket bolt. As the following image shows.
Continue reading Further Refinement of Motard Brake Bracket