Mike Bean's New Build (125cc w/4 Speed)

[Mike Bean]

Day #1 in the Barstool Racer Garage was a Success!

I built the start of a new frame, did some mocking up of the engine under the stool and then built new engine mounts.

I used 1" X 2" 1/8" steel channel for the frame cross supports. I then took some 1/4" X 1-1/2" Flat and use that for the rear mounts and then took another piece of 1" X 2" X 1/8" steel channel and use that for the front center support. I am thinking about adding a couple of angled side braces to the front center support to prevent left and right movement... What do you guys think? Is it really necessary?

I could not have asked for a better fit with the engine under the stool. The engine looks large, but it is actually very compact and fit better than expected.

Does anyone know what size chain these engines use?

I took some measurements of the sprocket and this is what I have:
Sprocket thickness .313
Tooth Spacing (tip-to-tip) .561
Total Teeth 12

Thanks!

Below are photos of todays build... :smash:

1098

1099

1100

This is a solid mount. If anyone has an idea on how to add some rubber mounts let me know.

1101

Same as rear, solid mount. I need to add some type of rubber mount at the bottom of this mount, not the top.

1103

That's all Folks! :wave:

[elvergon]

Can´t see the pics =(!

[Woodchuckscustoms.com]

Looks Good Mike I just might come to FL. and take it for a Rip Ride I mean a test drive:thumb:

[Mike Bean]

Can´t see the pics =(!

Elvergon,

Do you see broken image links when you view the post? What web browser are you using?

Is anyone else having a problem with viewing the images?

Thanks,

Mike

[Mike Bean]

Looks Good Mike I just might come to FL. and take it for a Rip Ride I mean a test drive:thumb:

You will have to earn the ride by building a BSR that is faster... :laughing:

[tharaw]

nop no pics here

[Woodchuckscustoms.com]

You will have to earn the ride by building a BSR that is faster... :laughing:

Ok Mike I have a 600cc triple yamaha motor I think that might just smoke the 125cc:thumb:

[rednecktech]

my honda 125 runs a 428 chain and sprocket set

[Chevy2ride]

I see the pic's just fine.:eek2: Looks like it'll be smokin when it's done.....:hot: How many gears does it have?:cussing: You might need a chute to stop it:bigcry:

[Mike Bean]

Ok Mike I have a 600cc triple yamaha motor I think that might just smoke the 125cc:thumb:

Ok, that's great...but I do not see it in a BSR... :laughing:

GET ER' DONE W.C.!

:cheers:

[Mike Bean]

Chevy,

The engine has a 4 speed automatic transmission. I am going to start out with a 25 tooth sprocket on the rear and see how it runs...

Mike Bean

[Woodchuckscustoms.com]

Ok, that's great...but I do not see it in a BSR... :laughing:

GET ER' DONE W.C.!

:cheers:
Ya I know. Not sure if i want to put it on a singles seat BSR But a double seater might be cool:thumb:

[elvergon]

yeah, that was the problem mike, I was using Mozilla Firefox. That BSR looks pretty cool. What you can do is get some rubber from anywhere maybe including the rubber washer kind and insert it between the mount and the engine. Thats the way to go. Keep us posted

[Mike Bean]

I think I am going to go with a chain tensioner for the build because the engine is going to be a fixed mount.

Has anyone done this before or know how to build one? I have a source for the tensioner sprocket, I just need to figure out how to build it.

Anyone got any photos of a simple setup?

Thanks!

Mike Bean

[elvergon]

Just remembering Mike, If you use a sproket the same size as the cycle had you will burn the engine cause it will rev very fast, due to the change in wheel size. Try using something a little bit bigger than the sproket of the engine. Anyway youll have wheelies in all 4 gears :D

[Mike Bean]

Elvergon,

I am going to start out with a 25 tooth and see how it goes. From what other had posted in the forum, the 25 tooth will be a good starting place.

With this engine, I should be able to get a nice balance of power and speed. I want to be able to spin the tires in first gear (in the grass or dirt) and also be able to run out the RPM's at a medium pace so I can get some nice acceleration in each gear without having to shift quickly...

Mike

[sweav]

Hey Mike, hows the build coming along?

[Mike Bean]

Hey Sweav,

I have not had much time the past two weeks. I just found out what size chain the front drive sprocket is, so now I can look into a rear sprocket and move on with the build.

Because the engine is going to be a solid mount, I need to align the drive sprocket and rear sprocket before I weld.

Hopefully next weekend I can get more done...

Mike

[Terry Skinner]

Because the engine is going to be a solid mount, I need to align the drive sprocket and rear sprocket before I weld.
Mike

Doesn't your rear sprocket slide back and forth on the axle?? Or are you saying that you are trying to get the engine perpendicular to the axle?? I would think that you could take one of the covers off the engine and lay a straight edge on the gasket surface. That would give you a datum line that you could make parallel to the frame rails. Did you pin it down as to which engine you have?? Enquiring minds want to know.........Terry

[Mike Bean]

Terry,

The engine is not going to have any left to right movement to square up the drive sprocket with the rear sprocket. I am going to need to place a sprocket on the rear axle and then use a straight edge to be sure they are in alignment.

As for the engine, it is a Suzuki 125CC. I believe it was made in 1984 for a three wheeler.

Mike

[Mike Bean]

I got some more time now to put into the new build.

Today I finished up the new motor mounts and finished welded them in. Now that the hard work is done, the rest will be easy...

Check out the rear sprocket. It is a 28 tooth #428 chain. This BSR is going to fly.... :thumb:

I will be doing more finished welding tomorrow and cutting the rest of the parts during the next week. Hopefully I can have it done in a few weeks.

I have attached a few photos of todays progress...

Mike
:hot:

[Mike Bean]

I see the pic's just fine.:eek2: Looks like it'll be smokin when it's done.....:hot: How many gears does it have?:cussing: You might need a chute to stop it:bigcry:

Chevy,

The engine has 4 gears with reverse. Just what I need when I run into something....

Mike Bean

[boxcar]

Hey Mike, say I noticed that your not using the top mount on the rear of your motor. Will this be OK. Reason I ask is I'm going to use a 305 twin Kaw motor and was thinking on doing the same thing. I just wasn't sure on how much torque the motor will create. Also can I ask where you purchased the axle hub and sprocket for your rear axle assembly. I'll be in the market when I get started. Thanks, boxcar

[Mike Bean]

Hey Mike, say I noticed that your not using the top mount on the rear of your motor. Will this be OK. Reason I ask is I'm going to use a 305 twin Kaw motor and was thinking on doing the same thing. I just wasn't sure on how much torque the motor will create. Also can I ask where you purchased the axle hub and sprocket for your rear axle assembly. I'll be in the market when I get started. Thanks, boxcar

Hey Boxcar,

I am debating on adding some side supports to the front mount to prevent left and right shifting. I will see what kind of torque the engine has when I start it up. For the 305 twin I would be sure you have some solid mounting for that thing.

As for the sprocket and hub, the hub is from a MCP hydraulic brake disc and the sprocket was custom made by a vendor for Barstool Racer Supply.

If you need a special sprocket and hub like that let us know and we can get one for you done. A 28 tooth is the smallest we can go for that hub.

Mike Bean

[boxcar]

Thanks Mike, couple more questions. Is the 28t sprocket the way to go. What I mean is, a person wants to go as small as possible your saying. Also, how does a person adjust his chain if the motor is mounted ridged. On the Briggs or Honda you make your self a slide adjustment like when I raced karts. Thanks for the info, BOXCAR

[Mike Bean]

Boxcar,

I am looking to go with a chain tensioner that has a solid mount if I run into chain tension problems. I did a quick mock up of the chain today and it looks like I may be able to put an offset link in and be fine.

There is a company online that has various chain tensioner for different applications. I do not know the link off the top of my head but I can get it for you if needed.

If I have to setup an chain tensioner I will post some photos of what I did.

The reason I am starting out with the smallest sprocket (28 tooth) is because there was some talk in the forum about someone else that did a build similar to mine and use I believe a 35 tooth and said it was too much gear, so I figured I would go less. I was originally going to use a 25 tooth, but the bolt fingers were about .030 larger than the cuts for the teeth so I went with a 28 tooth.

Mike

[boxcar]

Ok, Thanks again

boxcar

[tqm3]

Chevy,

The engine has 4 gears with reverse. Just what I need when I run into something....

Mike Bean

I wish:cheers: mine had reverse!

[elvergon]

You´ll be KD king of drifting with that engine ;). Is a differiential to expensive? Since you´re having such a nice motor, maybe one won´t be that much work.

[boxcar]

Mike, sent you a pm

boxcar

[BAR-TAB]

Man.........what are you gonna do with all that power?????? Be careful Mike.

[Mike Bean]

Man.........what are you gonna do with all that power?????? Be careful Mike.

Bar-Tab,

I have not figured that out yet. :dizzy: But it never hurts to have way too much power just in case you need it.

We do have a lot of scooters and 4 wheelers running up and down our street here, I think I will try to get into some races and show what a bad ass barstool can do. :laughing:

Mike
:cheers:

[mrpenguin]

Mike, wanna see where I cracked 2 ribs? PS I know darn well that's a potato gun in the corner of the picture. Just what do you intend to do with THAT!?

[Mike Bean]

Mr Penguin,

It is not a potato gun, it is a potato cannon. :laughing:

It will shoot a potato a little over 1100' straight up and further than the eye can see when shooting at a 45 degree angle.

I usually charge the chamber with 100 PSI and let it rip with my custom made quick air release valve.

I was wondering if someone would notice the gun and comment on it... :cheers:
Oh yea, did you crack your ribs on the BSR? I have fallen off a few times riding wheelies, but nothing serious .... YET!:blob_red:

Mike

[mrpenguin]

I'm a potato gun guy from way back. However you should always use Aqua Net hair spray and give it a slow 15 count before capping the chamber. A Coleman lantern igniter works well to touch it off. I guess I just like the pretty colors at night coming out of the barrel.
Yup, the cracked ribs were from my maiden voyage on the stool down my gravel driveway. The racer went down sideways and the hand grip got me right below the left pit. That's more than I told my wife so I'd appreciate a little professional courtesy on this. Mr P

[BAR-TAB]

I sorta kinda almost ate in front of 50 people at a harley dealer.lol.
. I have a platform on the back of my stool I stand on and ride wheelies. gave it too much gas and came over and beyond the wheelie bar. I took the grip tape in the shin and got a 6 inch strawberry from it, but managed to recover without falling. Til.next time. hehe

[Mike Bean]

I'm a potato gun guy from way back. However you should always use Aqua Net hair spray and give it a slow 15 count before capping the chamber. A Coleman lantern igniter works well to touch it off. I guess I just like the pretty colors at night coming out of the barrel.
Yup, the cracked ribs were from my maiden voyage on the stool down my gravel driveway. The racer went down sideways and the hand grip got me right below the left pit. That's more than I told my wife so I'd appreciate a little professional courtesy on this. Mr P

From the research I did on potato cannons, the use of compressed air has much more power then the hair spray type and they are much safer... I am all about the power, forget the safety.. :laughing:

As for the BSR Maiden Voyage, I believe another member on here during his first few rides went over the handle bars...I wont mention any names..sweav...:wave:

My maiden voyage did not have any bad spills, but that was only 6.5HP and a TAV. Now I have a 125CC with 4 Gears!!! More Power!

I am thinking up a design for some stable wheelie bars to ride wheelies at 40 mph and in all gears if necessary. :blue_blob:

Mike

[Mike Bean]

Ok, I finally got the base frame fully welded now and got a chance to mount the engine in and start it up.

The engine ran great, no smoke, all the gears went in smooth (including reverse :thumb:) and started back up on one short pull.

I found out after rebuilding the carb twice and the pull starter once that the reason the engine would only run for a few seconds at a time was because the coil mounting bracket needed to be grounded. I am pretty good with engines, but did not know this.

I have attached a few photos of todays progress. The only thing left is to mount the front spindle brackets, finished the steering handle bar and fab up the hydraulic brake mounts.

If everything goes according to plan, I will be driving the new BSR by the end of next week.

Mike Bean

[mulisha-troopa]

wat brakes are you gunna use 2 slow that baby down??

[BAR-TAB]

knees and elbows................lol

[Mike Bean]

wat brakes are you gunna use 2 slow that baby down??

Mulisha,

I was going to show you a photo of my hydraulic brake system, but the camera was dead. But yes, hydraulic brakes all the way. And if they fail, I will use what ever I can put to the pavement as BAR-TAB mentioned...:laughing:

I am hoping to get the pig running this weekend....yes..again...this weekend...anyways if I do I will post some photos. There is so little left I really need to get to the grind and get it done.

Mike Bean

[BAR-TAB]

better git busy then lol

[Mike Bean]

Finally, I got the pig running. I took it out for a quick test right tonight and I need to setup a chain tensioner. I was 1/4" shy of using a half link and not needing a tensioner.

But the BSR ran great and sounds good. Reverse worked great also.. :cool_dude:

The sun was going down so I will post pics of the finished but not yet painted tomorrow...

Mike

[freak]

Reverse , lol , That's killer. Can't wait to see the pics and here more on how she runs. I'm thinking of getting a honda clone 150cc off a friend . I was thinking of making a mini trike but i'm leaning toward a kick'n BSR.

A tensioner should be a pretty ez thing to do. My Q: is how did you mate the sproket on the engine to the one one the axle. I assume the axle is a #41 but what's the drive sprocket ?

freak

[Mike Bean]

My Q: is how did you mate the sprocket on the engine to the one one the axle. I assume the axle is a #41 but what's the drive sprocket ?

freak

The drive sprocket on the engine is a #428 chain. I had a custom 27 Tooth rear sprocket made to match the drive. I used a MCP hydraulic brake disc hub for the rear sprocket hub so I could get down to 27 teeth.
This BSR is going to fly in 4th gear.... :hot:

Mike

[Mike Bean]

Ok, got some photos today for your viewing pleasure.

I included close ups of the hydraulic braking system and how I relocated the ignition coil and module in case anyone is interested.

I should have the chain tensioner done this coming weekend and then it will be time for some videos... :thumb:

Mike Bean

[freak]

Amazing !!!

[Redrooster]

Great job mike.... What color are you going to paint this one?

[Mike Bean]

Great job mike.... What color are you going to paint this one?

Well I am thinking about another red one. But this time I am going to change up the color red. Chuck from WoodChucksCustoms told me about a color called Anodized Red by Dupli Color that is really sharp, so I am going to take a look for it.

I still have to make some wheelie bars so I wont be painting for a while yet. And I think I may be able to hook up some lights to it also. There is an extra wire coming out behind the stator assy and it goes to nothing. I am assuming it is a 12V feed for lighting. I will get the volt meter out this weekend while fabbing up the chain tensioner bracket.

Mike Bean

[elvergon]

Hey Mike, my engine is a Honda 125 cc and has also a 12 tooth sprocket.
I ran it nicely with a #40 chain. Maybe getting a 40 chain its easier than a 428. Maybe not!

Nice job anyway.

[Mike Bean]

I finally got to take it out for a serious test drive today. I fabricated a bracket this afternoon for the chain tensioner and it worked great.

The rear sprocket is a 28T and the over all acceleration was very good. 1st gear a little low, 2nd - 4th really picked up some speed. 3rd and 4th gear really fly. In second gear going about 10-15mph I can hit the gas a lift the front end with ease.

The handling at high speeds seemed to be a lot smoother than with the 6.5HP Tecumseh engine. I think there is less vibration, not sure.

Reverse works great, it is nice to have.

I also found out the extra wire off the engine is a 12V feed, so I am thinking about some lights for night driving.

Tomorrow I am going to get out the GPS and get some speed runs in and see what it can do.

Below is a photo of the chain tensioner setup if anyone needs one for their BSR.

Mike Bean

[freak]

that look great !! I bet it can pull the wheels in ever gear. You might want to put a back brace or sissy bar on that thing. lol

How are you shifting ? Does the shifter lever come out far enough to use your foot ?

[Mike Bean]

Hey Freak,

As for wheelies, I just hang on, I am not going to fall off the back. It is just like riding a motorcycle in a sense.

The shifting works great. When I first started building the BSR, I setup the engine to be sure the shifter was out far enough on the left side.

The only thing I don't like is the up-shifting. You need to ware shoes and lean a little to the left to get your foot under the shifter. I guess those are the things you have to deal with if you want gears.

Mike

[freak]

you gotta get some video for us. It sounds like a blast. It also sounds like you got the shifting the way you like it. I was just wondering if you were going to add a linkage to the shifter and put forward controlls on you foot peg.

I don't wanna start a new thread so i'll just ask here. How's the handling with those tires as appose to slicks ? When i build mine i'll be running on pave and grass and i'm pretty sure those are far better on grass.

[Mike Bean]

Freak,

I think I am going to leave the shifter where it is. If I want to ride at a medium pace I can put it in second gear and even start off from a stop in second gear. Third gear has plenty of speed, so if I am out somewhere I don't see a real big need for shift all the time.

As for the tires, they handle great! Very smooth ride, they don't pickup rocks or pebbles and the are great for sand, dirt or grass driving.

Mike

[freak]

Alright all i've seen for rain tires ( that's what ther're called rite ) is 5" and only saw those on ebay. So where do you get them and are they 6" or 5" ?

[Mike Bean]

Freak,

Click on the link below and in the thread I give all the details on the rims and tires.

http://barflyracers.com/showthread.php?t=18 (http://barflyracers.com/showthread.php?t=18)

Apskarting.com (http://apskarting.com)carries the same ones.

If you go to the BarstoolRacerSupply.com (http://barstoolracersupply.com)site and on the first page there is a link for the latests parts listings, click on that link and the actual APS Karting part numbers are in there.

Mike Bean
:hot:

[Woodchuckscustoms.com]

Hey Freak,

As for wheelies, I just hang on, I am not going to fall off the back. It is just like riding a motorcycle in a sense.

The shifting works great. When I first started building the BSR, I setup the engine to be sure the shifter was out far enough on the left side.

The only thing I don't like is the up-shifting. You need to ware shoes and lean a little to the left to get your foot under the shifter. I guess those are the things you have to deal with if you want gears.

Mike



Mike check out some of the old harlys the ones that have suiside shifters I bet that would work the tits.:cheers:

[elvergon]

We neeed some vids of that beast Mike

[moto1fast]

Hey mike have you thought of a heel- toe shifter? They have them on four wheelers so you can shift if you have floor boards. May be able to adapt one on yours with out much trouble! Cant see how much room you have at shifter. Like the chain tensioner! get some video of it being put through its paces! Good Job!!!:thumb:

[pupuslinger]

here is the shifter i did, i used a wheel for a handle, it matches the wheelie bar. it works good but when you bang the gears, you only have one hand on the wheel. :dizzy: so i wouldnt recomend it for racing. but it is kinda cool, most people notice that first thing. they say " oh man it has gears, thats crazy "

[moto1fast]

VERY NICE!! GOOD JOB!! The Shifter does give it that " OH COOL LOOK" !! What color are you going to paint it? Green to match the seat? Looks Great !!:thumb:

[elvergon]

Pupus do you have clutch? If so do you activate it with the right hand or what?

[moto1fast]

If I aint mistaking it has a auto clutch system! When you shift it disingauges the clutch and when you let off the shifter it ingauges it! You shift and hold it, rev engine up and release it and BANG your gone!! LOL Cool system and works great!

[pupuslinger]

yeah, it has an auto clutch, much nicer for just tooling around. the only problem about holding mine and reving it up and letting go is that you would only have one hand on the wheel, not sure how that would go. shifting with the hand is cool for casual stuff, but banging gears you would want a foot shift.

[moto1fast]

I have found out that if you want to bang gears and only have one hand on the steering wheel position your hand in the middle of it at the top of it or middle bottom! I feel you have the most control in those positions!I use the bottom middle position because when I bang gears it tends to pull you backwards and if your hand is at the top of steering wheel it can cause you to pull on the steering and cause you to turn the steering wheel. In the bottom middle position when you pull back on steering wheel during banging it keeps you straight! Also you would not want to bang gears in a turn with it! LOL:laughing:

[Snakester]

The first BSR that I rode had an 8" dia.steering wheel w/10" deep type w/a coolie cup mounted in the center. Just didn't feel comfy doing wheelies w/a steering wheel and after I spilled my BREW , I have been a handle bar man ever since!:lush:

[elvergon]

I have found out that if you want to bang gears and only have one hand on the steering wheel position your hand in the middle of it at the top of it or middle bottom! I feel you have the most control in those positions!I use the bottom middle position because when I bang gears it tends to pull you backwards and if your hand is at the top of steering wheel it can cause you to pull on the steering and cause you to turn the steering wheel. In the bottom middle position when you pull back on steering wheel during banging it keeps you straight! Also you would not want to bang gears in a turn with it! LOL:laughing:

Yeah! I learnt that while going on 3rd mid revs....

Almost hit 3 cars but luckily it didn´t tip over! :D

[elvergon]

If I aint mistaking it has a auto clutch system! When you shift it disingauges the clutch and when you let off the shifter it ingauges it! You shift and hold it, rev engine up and release it and BANG your gone!! LOL Cool system and works great!


DAMN IT! I need one of those engines...

My BSR clutch is messed....Damn..!!!

[Mike Bean]

I know it has been a while since I have posted anything on the 125cc build.

I got kind of busy with other stuff and neglected my BSR for awhile. Now I am back on track again and today I was re-working the chain tensioner to be a solid design instead of a spring loaded type. What was happening when I would run in reverse the chain tension would unload and cause the chain to slip on the front sprocket.

Today I rebuilt the bracket and more than doubled the chain tension with the spring and still the same problem, so I am going to fab up a solid mount for the wheel and that should fix the problems.

After that it is onto the wheelie bars, head lights and one tail light.

That's about it for now... I will post more with photos and I complete the small project left.

And yes there will be some video soon. The BSR won't be painted yet, but there will be video.

Mike Bean

[elvergon]

we waiting then!

Nice to know you´re back =)

[moto1fast]

Oh yes, The old chain jumping over front sprocket while in reverse problem! The Chain tensioner must be solid or adjustable to keep from it unloading in reverse! You could put 50 lbs of tension on the spring loaded one but it would still jump because of the reverse torque wieght the tensioner recieves is equal to the wieght of the Rider, BSR wieght, and Torque of the engine combined. Up to 300 lbs of wieght on tensioner. So when you build your solid one make sure it can handle that much torque wieght! Hope that helps mike!:thumb:

[Woodchuckscustoms.com]

Video sounds great! I can't wait to see this bear in action Mike. Once ya get the hang of driving it you should tri some reverse curls with it and smoke the tires off it!:hot:

[northof50]

You can try boring out the hole in the motor mount big enough for like garden hose and the bolt in the middle, or else rubber mount the bar stool and steering.

[Neverdone]

Just wondering how did you build your tensioner? Do you have any pics? Also can you still get that sprocket and hub that you had costum made, I did not see it on your website. I am building my BSR with a 2 Stroke 125cc yammaha 5 speed manual clutch. I had planned on using a 40 tooth sprocket will that be to big?

[dogbarstools]

Where did you get that tensioner?