Tag Archives: motorcycle

Please Don’t Ever Do This!

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!

Motard Complete & Tested

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

Adapting a Motorcycle Engine to a Go-Kart

A recent project was figuring out how to adapting a YZ-125 motorbike engine to a go-kart frame.

20151005_124641A 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

Further Refinement of Motard Brake Bracket

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.

Front Fork and Brake_Lite_Weak spot Continue reading Further Refinement of Motard Brake Bracket