My 1st Trials Bike (part 2)

In the last instalment, my home grown trials bike was converted from a Greeves roadster with a 225cc 2-stroke villiers engine and Ariel telescopic forks.
The next major change to the bike came about because I aquired a 250cc BSA C15t 4-stroke engine with a broken gearbox, but with insufficient funds for the repair I managed to find a local bike dealer who was prepared to supply me with the replacement parts for the repair, in exchange for the 2-stroke engine, (who said the days of barter were over.)
The next job was to shoe-horn the engine into the Greeves frame whilst keeping the gearbox sprocket in line with the rear wheel sprocket. This was achieved with more hack-sawing and grinding of the ever diminishing engine plates, the lower engine cradle now acted as an integral bash plate to protect the sump. The interesting thing was the fact that in spite of the taller 4-stroke engine, I managed to maintain, if not, slightly improve the ground clearance. There was an airbox / battery box in the centre of the frame which also doubled as a structural member of the frame, so this was done away with and a bespoke oil tank was fabricated to take it's place. There were other things to make, like an exhaust system, an air filter, a battery holder which was mounted behind a plate sandwiched between the fork legs, underneath the top yoke, and so on.
If I had my own welding gear, all of this would have been so much easier to do, however, the truth of the matter was that all of the mods required had to be mocked up and prefabricated before I could get to a friend of mine who had the welding equipment.
It was the little things that took the time, like cutting out fashioning a rear brake lever from a piece of dural plate to make a rear brake lever and connecting this to the hub via a cable
This little beauty ran really well and was trialed for 3-4 years and was quite competetive in a world that was now being dominated by the new wave of Spanish marques.
After a time, I too was won over by the much lighter more powerful 2-stroke machines that were to drive the 4-stroke powered bikes into obscurity. The interesting thing is that now 4-stroke bikes are coming back to rule the roost.
When I think back on this project, I seem to recall that apart from a small selection of spanners, all I had for the fabrication was a hacksaw, a couple of files, one flat and one round, a DIY type electric drill with a few drill bits.
It's surprising what you can achieve with a bit of vision, a few tools and a low budget.

Now the job would be so much easier when you have the right tool for the job.

AHRMA TRIALS 1976 Honda TL250 KICK START IDLER GEAR
AHRMA TRIALS 1976 Honda TL250 KICK START IDLER GEAR
Paypal   £12.62
KAWASAKI KT250 TRANSMISSION GEARS TRIALS 75 76 KT 250
KAWASAKI KT250 TRANSMISSION GEARS TRIALS 75 76 KT 250
Paypal   £27.84
YAMAHA TY175 TRIALS 75 79 2ND PINION GEAR NOS OEM
YAMAHA TY175 TRIALS 75 79 2ND PINION GEAR NOS OEM
Paypal   £15.81
PUTOLINE GP10 GEAR OILSHERCOBETASCORPATRIALSMOTOX
PUTOLINE GP10 GEAR OILSHERCOBETASCORPATRIALSMOTOX
Paypal   £10.99
TRIAL GAS GAS PRO RAGA GEAR SHAFT SECONDARY AXIS MT280236075
TRIAL GAS GAS PRO RAGA GEAR SHAFT SECONDARY AXIS MT280236075
Paypal   £89.95
Sherco Trials Bike Gear Lever STD 1999 2010 NEW
Sherco Trials Bike Gear Lever STD 1999 2010 NEW
Paypal   £44.85
Sherco Trials Bike Gear Lever RACING 1999 2010NEW
Sherco Trials Bike Gear Lever RACING 1999 2010NEW
Paypal   £43.45
1975 Kawasaki Trials KT250 Engine Gear Shift Shaft
1975 Kawasaki Trials KT250 Engine Gear Shift Shaft
Paypal   £25.30
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