Winter is over

[Wolf]

...what I've done in the dark days (although, considering the recent situation, it's still dark). My intention was to reduce a little weight of my 450. I've replaced the side stand with that of a RT, the battery and the driving chain with lighter parts. Also, I made some parts out of aluminum to replace parts made of brass or steel. The overall weight reduction is 4,5 kg, not that much. But being in the workshop is fun too. I've also spend some money on the fork internals, this is really a huge improvement.
The front brake works very fine now.

Cheers

Wolf

[graeme]

Nice job Wolf,,,,,

What did you do to the fork internals ?
Is that a magnet in the oil dip stick ?
520 chain and sprockets ?

Graeme

[Eldert]

converting to 520 chain you can use a Honda CRF 150 front sprocket

520 conversion 001.JPG

for the alternator outlet you can use a 35mm Marzocchi fork cap on a late type crankcase .

Eldert

[Wolf]

Hi Graeme,

I'm using a 428 chain, front and rear sprocket are available for the Scrambler models (or could be machined to fit from 530 parts).
The fork was completly rebuild by hh-racetech.de, now it has a compression and rebound damping unit. Sounds may be a bit overdone and it is not unexpensive, but hey.

The oil dip stick is completly self made (I know they are available) and fitted with a neodym magnet.

Hi Eldert, this is a really good fancy idea using the fork cap. But I also liked the idea using the cable seal system from the later Ducati models.

Cheers

Wolf

[Wolf]

...I've just checked, the thread of the fork cap and that of the cable port are not identical on my bike...

[Eldert]

Hi Wolf

early Marzocchi 35mm forks M30 X 1 threads . late Marzocchi M30 X 1.5 threads

Eldert

my oilfilter :

alu oil filter.jpg

[Wolf]

very nice!

[ducwiz]

Wolf,

from your photo it's not clearly visible which battery type you have installed. If it is stille a lead/acid you can cut an extra kilogram by changing to a LiFePO4. Also possible: use a voltage R-R that can operate with a large electrolytic capacitor as a short-time battery substitute, or even has one built-in. Such R-R makes a battery obsolete.
And a tip, from my own experience: omit the rubber bellows between carb and filter box. Run the machine with a K&N filter or similar. Will work much better. However, you might have to play with the jetting etc. to find the optimum working adjustment.

cheers Hans

[Wolf]

Hans,
you are absolutely right, the lead/acid battery is the item if replaced saves the largest amount of weight (at the lowest costs!). In my case the new LiFePO battery has 1.4 kg less.
And yes, the odd rubber bellow is maybe the worst tubing possible considering it's fluid mechanical properties. I will consider a K&N filter type. On the other hand, I like the looks of the round air filter. And again, there is some additional potential for weight to be saved….I will see.

Kind regards

Wolf

[Wolf]

...another winter is gone and some lightweight parts made:

a titanium front axle and aluminum nut - weight saved comparable to two chocolate bars