Weldangrind's New Lifan GY5

[Weldangrind]

Originally Posted by tankme

Setting the bar high again! Really nice work Weldandgrind. It seems like I am going to be doing the same thing.

What type of steel pipe did you use for the mid-pipe area, or use typically for exhausts? Is this something found in a local pipe yard, or can onlinemetals.com satisfy for this small project? (Driving to town from the sticks costs me $32 so online is my first choice.)

Thanks!!
Jim

Thanks. I can't recall what I used, but I doubt that I would have used DOM, because it's not necessary for this task. Probably just mild steel tubing, and I was more focused on the size than the material.

The mandrels I have with my tubing roller don't match the specific size I was bending, so it creased the tube a bit. It still flows.

[tankme]

Hmm, what is DOM?

Thanks!
Jim

[Trailbikeryder]

Nice Progress

[zingshoen]

nice simple instrument setup. are you going with the honda silver red colour scheme?

[Weldangrind]

Originally Posted by zingshoen

nice simple instrument setup. are you going with the honda silver red colour scheme?

Not on purpose. The frame is a sort of silver / grey, and the plastics will be black and red with a black seat and black tank. I've changed the bike quite a bit, but the registration says red, so I don't want to stray too far.

I like the instrumentation as well. I have no need for a tach that lies to me, and I like the Roketa speedo.

[Weldangrind]

Forum member Atomic Wedgie welded my aluminum headlight frame for me, since cracks developed on the corners from bending. He also added some extra pieces for strength.

This is an action shot of TIG welding in progress.



And this is the frame mounted to the forks with stainless T-bolt clamps.

[satelliteone]

looking very awesome

[Weldangrind]

Originally Posted by satelliteone

looking very awesome

Thanks! I hope to complete it this weekend and go for a victory ride.

[FastDoc]

Wonderful work.

I love the action shot.

The exhaust is looking great.

The XR exhaust is durable and quiet. You will love it.

[Weldangrind]

Originally Posted by FastDoc

Wonderful work.

I love the action shot.

The exhaust is looking great.

The XR exhaust is durable and quiet. You will love it.

Thank you.

The XR pipe sound volume will depend upon which insert I use with it. The 2002 version is a quiet core, but my '96 is nearly wide open. We'll see which one sounds better and is less obnoxious.

[Weldangrind]

I made a bunch of progress over the weekend. I completed the wiring over the weekend, and I discovered that the audible turn signal box is quite necessary, since there's no quick way to incorporate a flasher. There is a nice by-product of the box, and that is that the turn signals flash rapidly nine times when you apply the brake. Since Son of Weldangrind will be the primary pilot, I'm happy to know that the Lifan has this safety feature.

I discovered an oddity. I had unplugged the alarm, without knowing how it interacted with the electrical system. The bike started up fine without the alarm, but I couldn't switch it off! Neither the kill switch nor the key switch had any effect on the engine, yet the key switch could shut off all electrical accessories. The solution was to simply plug the alarm back in, minus the loudspeaker. The kill switch and key switch now work properly.

I hope to get some time on the bike tomorrow evening, at which time I'll install the front brake (and flush it). After a little tuning, it should be ready for a maiden voyage. I'll post pics when it's done.

[SpudRider]

I'm glad to hear you are ready to test the bike, Weld.

[FastDoc]

This is going to be a great motorcycle, Weld!

[MICRider]

I can't wait to see some pics of it all put together, your doing an awesome job on it!

[Weldangrind]

Thanks guys.

I got a little more done tonight, after getting home quite late from work. I installed the front rotor, cleaned the master cylinder, flushed out the old fluid and bled it. I then tried two new CDI's that I picked up today; one (that I bought from Phil at Adventure West) worked great, while the other (that I bought at Saga) runs great but ignores the kill switch. To top it off, they won't accept returns of electrical parts. At least it would get me out of a jam, and i can always stall the motor.

I'm struggling to get the carb dialed in, since the slow jet I've installed might be too big (it's a 30). I'll try a 22.5 that I have and see if it helps.

I also used Spud's hose clamp trick to mount the USD fork guards. Thanks Spud!