Re: Karizma Scrambler-ish Build

Thread approved.

Re: Karizma Scrambler-ish Build


Eagerly waiting for the next update !

Re: Karizma Scrambler-ish Build

bring it on brother

Re: Karizma Scrambler-ish Build

Thank you cobraking1993 for quoting my post,after you quoted I got an alert message and came to know that my thread was approved.

Few points I would like to mention

>This is my first ever attempt to do fabrication/modification on motorcycle so things may look immature.
>The motorcycle is at my home town, I get only 4-5 days in a month to do the work, so
updates will be slow.
>Few parts I have already procured, I regret not starting the thread earlier, I would have got pointers.

Below is the plan for my build

1>Alloy wheels to be replaced with spoke wheels.
2>Round headlamp.
3>Front forks to be replaced.
4>No body panels,fairing.
5>Fuel tank to be replaced.
6>Seat frame/rear frame will be modified for flat style seat.
7>Monoshock at rear.
8>Airfilter box will be removed, K&N will be used,planning to fabricate box for it.
9>New handle Bar
10>Aluminium Bash plate.
11>Wiring,Electrical’s tray and Battery box needs to be fabricated.
12> Both Fenders will be replaced.

There are many points on which I have not decided yet and I expect to encounter lot of mods as I continue the work.


I decided to start with wheels first, I asked few places about which wheels are compatible and direct fit in Karizma.
Everyone said go for CBZ classic rims.

I started to hunt for them and found OE rear Rim and Front Hub,I could not find Rear Hub,Front Rim and spokes.
CBZ uses 1.85 size front rim,compared to 100cc bikes which use 1.60 size.

I searched online and found all three on safex,this was the moment i thought what the fuss ,everything is available so readily.

When I opened the delivered items reality hit me.



How can someone screw up things so bad.

1> Ordered front rim,it was 1.85 size OE make in description - I got after market 1.60.
2> Ordered Rear Hub,OE and got clutch center.
3> Ordered spoke set rear and front and got 72 spokes of same size thrown in the box,someone didn't even bother to tie them.

I called them and tried to explained they said this is what you order.
After explaining a bit politely in proper tone they accepted their mistake.

Hero Motorcycle wheels have 36 spokes,All 36 are not same, It has 18 Outer and 18 Inner.
There is a difference in angle at J bend and also there is difference in length (approx 1 mm).
Rear are 161 mm and 161.6 mm. Front are 195 and 195.5 (CBZ Classic)

I have seen in aftermarket spoke kit (ex Gabriel for splendor) they provide all 36 spokes of same type.I think cost cutting and they think it dose not make a difference.

But most spoke wheels have two different set of spokes.

The OE Front Hub i purchased was grey so I thought of painting it black and i got brilliant idea of using spray primer filler.
Ordered Rustoleum Primer sprayed it and left for drying but even after a week it did not dry.
Had to scrub it off and then painted with 3 coats of black and 3 coats of clear. (Spray cans - Nippon)



I may have got old stock and that may be the reason for not drying.



I got good results with Nippon spray cans.

Re: Karizma Scrambler-ish Build

The hunt for CBZ front wheel and rear Hub did not go well.

Also deep down I was not happy with the choice of wheels,The CBZ wheels are strong but I am not sure whether
they would hold for where I plan to ride the Bike.

I placed order for Impulse front forks at dealership and received them. Price was around Rs 2700 odd per fork.(I think prices are revised recently and cost has gone to 3300)
Both Karizma and Impulse has 32 mm fork diameter so almost a direct fit.
Also we do not have lot of options,Xpulse has 37 mm forks ,meaning to fit you have to modify whole triple tree. Xpulse forks now cost around Rs 3400 per fork.

When I got Impulse forks I had a thought ,why not Impulse front wheel too? They are intended for off roading.

The hub of Impulse and CBZ are identical so I had to get Rim and Spokes.
Placed order and received Rim and spoke Kit.Tyre was purchased from Amazon,Original Size -Ceat make.

For fitting Impulse forks on Karizma you have to replace the Fork Cap with Karizma's Fork Cap
Impulse holds forks by pinching them at top bridge whereas in Karizma you have a bolt coming from top which threads on fork cap.





Fitting the forks is easy but the real challenge is to fit and make work the complete wheel assembly.I will explain in detail in next posts.



The impulse forks and wheel have increased the height considerably. IIRC the Impulse forks are 100 mm longer,add 12 mm increase due to bigger wheel (18 inch vs 19 inch).
Only one leg of center stand is touching the ground.
Effectively there is 112 mm increase in height, Original Trail length and Rake angle numbers have gone for toss.
Karizma has 26 degree rake and around 94 mm trail length.

Re: Karizma Scrambler-ish Build

Great work sir

Eagerly waiting for the rest of the story

Re: Karizma Scrambler-ish Build

The monoshock conversion was planned from beginning and had acquired Xpulse Rear Shock.
It is 10 step adjustable, Endurance make. It costs around Rs. 5500
Both Ends have 10 mm mounting hole, The width of mounts is 32 mm and center to center distance (mounting hole to mounting hole) is approx 310 mm.
I went through photos of monoshock mounts from different make and models to get idea
Finally decided upon below.



I visited the metal yard to get material for the mounts.
I was looking for 32 mm channel but found box section with exact 32 mm side also picked some metal plates of different thickness.


After some cutting and grinding got the required shape out of box section.I will be reinforcing the sides with additional plates.






The upper mount was a bit complicated but I was able to pull it off.
I got a 5mm thick steel plate and got a 45 mm dia hole turned from a lathe in it. The dia of karizma down tube on which upper mount is welded is 45mm.
I have a welding machine but I only tacked it,I got the mounts welded on frame from a professional.
The rear shock fouls with the rear frame support tubes so I had to cut them,they were to be cut anyways
as I am modifying the rear frame.


It is good to have two grinders,one with cutting wheel and one with grinding wheel mounted,you don't have to change wheels every time.
One is Bosch Make AG4 costs Rs 1800 approx other is local one Rs 1300
Also you can see Irwin combination square costs around Rs 1500 online,good for measuring and marking.















Next up Rear Wheel!!

Re: Karizma Scrambler-ish Build

I had gone for impulse wheel on front instead of CBZ and at I needed a strong wheel at rear too.
I looked for options but there was nothing that was direct fit,
Xpulse has disc brake at rear and hub is too wide for Karizma swingarm,
Similar case with Himalayan wheel.
I already had a CBZ rim,as I could not find a new Hub a got one from auto scrap yard.



As I thinking of getting it laced, I had an idea.
Xpulse Rim is also 18 inch so why not get the CBZ Hub laced with a Xpulse rear rim.
But there were lot of complications
Xpulse has
Straight pull spokes compared to J-Type of CBZ.
4 mm dia spokes much thicker than CBZ
8 mm dia nipples larger than CBZ.
Hence I had to find spokes which are of same length of CBZ but should by thicker so they fit in Xpulse rim i.e 161 mm and 161.5 mm,with 4 mm spoke thickness and 8 mm nipple size.
As I was searched online found that Royal Enfield Spokes are of similar length and thickness.
I visited RE Dealership with my Vernier and found right length spokes,I think they were from Thunderbird,the set costed around Rs 480



Got the rear wheel laced and fitted fitted 120/80 Tyre – Stock of Xpulse.



Finally started taking shape

Re: Karizma Scrambler-ish Build

Very excited for this project. Keep us posted. The way you have measured and documented everything will help many enthusiasts a lot. Thank you.

Re: Karizma Scrambler-ish Build

[MENTION=35113]tripster[/MENTION] Thanks.
One of the main reasons to start the thread was to document the build with as much details as possible.

As beautiful as Karizma Fuel tank is,it would not work with what I am trying to build.
Lot of people have used RX Tanks in their build, It is compact and has flat bottom line and hence it was decided to go for an RX100 tank.
I purchased a new Black RX 100 fuel Tank for Rs 4200 approx also purchased original fuel cap and mounting rubbers, I had never owned a Yamaha and was not aware that we still can purchase new RX Fuel tanks from authorized parts counter.



The tank is not direct fit on Karizma.
I will post in details about mounting RX Tank on Karizma Frame once it is completed.
Tank Slid in place on Frame



The Karizma frame tubes on rear sub frame are of 22mm diameter with 1.75 mm wall thickness (approx)
I think they are made of 1020 steel and are DOM (Drawn Over Mandrel Tubes) not sure though.
I procured 21.5mm diameter with 2.5 mm wall thickness steel pipes from metal store.
It cost around Rs 500 for 10 feet length.
It will be used for making rear frame (Rear Hoop and Support tubes)
I will be doing the welding from now on.



It is a ADOR 200A DC ARC machine costs Rs 25000.
I had also procured a TIG Torch set along with it.
You can do TIG welding with any ARC machine. You just need Argon Gas cylinder for shielding.
This machine is bit costly, you get machines for as low as Rs 3000,but if something generates high current and high temperature better to be on safer side.



I got the pipe bent into a hoop from machine shop having tube bender, charges Rs 50 only.



Point of No Return



I did a few adjustment on frame before setting up the Hoop



Pushed the tubes up with Hydraulic Jack , 4T purchased from amazon for about Rs 1600.

Did Some Leveling and alignment





Did a Dry Fit.








Looked good but I messed up.



The hoop is too narrow its only 170 mm wide, not wide enough to rest you back.

I tried to save it by doing some fabrication,

Cut it in half and welded a piece to widen it, but I did not like it.









It is scrapped.

New Hoop is in works.

Re: Karizma Scrambler-ish Build

Sorry for the late update
The bike is at my native place and I get to work only on weekends when I visit and if some
Other things come in way I do not get to work on bike.
-------------------------
So this time I asked pipe bender to use larger diameter die.



As the bender was not expert to put a kick up at end of hoop ,I cut some notches and bent it upwards.



Did some test fit of the Hoop





And Test fit of entire rear frame.



The hoop is supported by two down tubes which forms a U at bottom which will be welded to the frame.
I used two elbows, These are available ready-made Rs 25 per piece.



Pipes cannot be connected straightaway with one another as we can connect square tubes.
Due to circular shape the pipes need to be notched/coped to form a proper fit.
One way to do it is to use a online notching calculator
I used this one



You enter the values in the boxes and it throws out a pdf.



The pdf can be printed to 1:1 size or you can directly trace the design on the paper from the screen.



The outline needs to be pasted on the pipe and marked portion cut off



After grinding bit by bit we get a fit



Not bad for first try.

Brought a steel bar from metal yard and got it turned into dowels to assist fitting of tubes.
Rs 40/kg and some Rs 100 for lathe work.





Tacked in Rear Frame.



I painted it before hand as it would be difficult to reach tight spots later.
I have to paint it again at weld spots and give it a clear coat.

It is not fully welded yet.

Re: Karizma Scrambler-ish Build

Keep posting mate. This is one build I would love to ride.

Re: Karizma Scrambler-ish Build

Keep us posted about your progress

Re: Karizma Scrambler-ish Build

You are invited,sometime in June as it is my estimated time for completion.

Sorry for the late update.
Caught up in other work.
---------------------------


I had foam of other motorcycle seat which I decided to use for making the seat.
Marked the foam with rough outline.
Major chunks of foam were cut with retractable blade.
Then shaped it with a hacksaw blade to remove bulk material ,sand paper and scotch brite pads were used to smoothing and fine shaping.
As I doing it for first time,it was tedious and slow.I could have given to seat maker who could have done it in fraction of time, but then there would not be any fun and learning.



















I had procured scrap stainless sheet for making seat base, It is thin but very rigid and hard
It chewed up lot of my cutting discs in very short time.
























I used Araldite Rubber adhesive to glue the foam and steel base.
Searched Fevicol SR555 but did not find and went for Araldite.

SR555 costs around 500 for a kg and Araldite twice of that.



It needs a bit of finishing and then will take it to seat upholsterer and will see what he says.
I want flat seat with diamond stitching and have brown colour in mind.