Honda Super Chaly thread (Chaly restoration/modification)

[Sailorman]

Yes, I heard that about the Singapore 200cc limitation. I travel to Singapore to shop/get my civilization fix about every 5 months and have seen a bunch of Phantoms there.

Well, when I return from OZ the fun begins. I really dislike riding in Cambodia (ridden in the wind for 54 years), but the hop-up build is the fun part. I was going to just do an over-bore of .050 on a new barrel, but this looks like more fun. I looked all over Southeast Asia for a hot cam (Honda Tiger-200), but nothing. The CRF230F hot cam is going to be a real score. I looked up the valve/cam duration for the CRF and the Phantom and it looks like the only difference is that the intake valve on the CRF stays open 5 degrees longer than the one on the Phantom, thus a better fuel charge and "hotter" cam.

I had also looked at dropping in a Chinese 250cc V-2, but don't really trust Chinese engines very much. I always did like big thumper bikes, BSA-441 Victor, AJS 500, Matchless, Yamaha XT-500, Honda Ascot 500cc. The Yamaha XT-500 had so much torque you could almost pull stumps with it. I was riding mine across the tundra in the Alaska Arctic and it was throwing clods of tundra in front of me, and on me.

[Sailorman]

Here's a picture of my Phantom head that I ported/polished. Substantially bigger than stock. Should go good with BBR Honda CRF230F high lift cam.

[AE86]

Today was a complete "fix the mistakes" day.

I pressed the front wheel bearings in and forgot to put in the shaft collar, so I had to knock out and destroy this guy.




Then as I when to test run the motor on my Cub, I found it had almost no compression. When attempting to tighten the head studs down (they seemed loose), one of them snapped clean off. Seems that buying Taiwanese head studs was not a good idea as they all (overnight) had stretched, so I had to disassemble the top end and reinstall a used set of originals. Reassembled the top end.

Then I found that because I had installed shocks from a Wave on the front that I forgot to take into account that I'd needed a wider axle to fit, so that left me with nowhere to go but to the kitchen and make some dinner instead.

Here's how it sits.

[Sailorman]

Fabrication, hunting parts and redesign, that the fun of a build like this. Keep at it, it looks like your doing a great job.

[General Chatter]

nitrous kit ....

[AE86]

Motor in




Taller final drive/chain/etc in.




Accessories and necessities






As it sits

[Milord]

AK, I really enjoy reading your builds. I think my guilty pleasure stems from the fact that my last "build" wound up in a bushel

basket, 40 years ago. 250cc Kawi SS, after seizing the engine in Decemberrr. ( no oil flow due to cold )

My ride these days is a Triumph 1050 Spirit, but @ $2000/year for insurance, is it worth it?

[Sailorman]

Love the Tach, did you get that locally? I had to send to the US to get one for my Phantom. Surprisingly enough you can get an N2O kit for a small bike.

[AE86]

@milord, my guilty pleasure is the T140E Bonnie. To me, whatever makes you happy is all that should matter, if you can reasonably afford it that is.

@sailorman, the tach I found locally off of some broken up Chinese bike. I think I paid $10 for it but I can't remember. It was just there on a pile of parts in Russian market, so I picked it up.

[StroppyChops]

Enjoying the thread AE - good stuff.