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**Zapps** · 11-26-2020, 09:47 PM

Re: Karizma Scrambler-ish Build

Good to hear that you're back onto the build.

Originally posted by curse View Post

Restart!

Lost lot of time due to ongoing situation as visits to hometown decreased.
Plus rains occupied my working area -front porch.

Anyways started work slowly.

Due to long rains and storage welded,ground unpainted parts began to rust so had to clean all these and repaint.

[ATTACH]256356[/ATTACH]

**curse** · 03-03-2021, 10:40 PM

Again As good as the Stock Karizma Footrest holders are they not suitable for offroad use ,they are cast aluminium and will break under load & impact.
I measured the stock footrest holders and fabricated with same dimensions from 5 mm steel plate.
For bolt mountings got spacers machined and welded to the plate.
The position is similar to the stock footpegs
I used Xpulse E footrests ,costs Rs 85 each only.

**curse** · 03-04-2021, 11:16 PM

Air Filter
Plan A was to use a K&N, but not directly on the carb but to route the piping and fit it in a box to protect from dust,water ,slush etc.
K&N had to be opted as there was no space to mount OE airfilter box,and fabricating a custom airfilter box with sheet metal was too complicated for me.
I brought the RC1060 conical model and 132 and 140 main jets.(Lot of people have researched and came up with this combination)
But when I got a 3D printer, I planned for a custom box.
Plan B , brought a Yamaha FZ-25 air filter.
It was painful to get the dimensions as the shape was complicated (tapered,rounded sides etc)
It took lot of time to measure ,design and print it.

Below link if anyone wants to see the time lapse of the filter box printing.

https://youtu.be/knAku51g4jQ

Test rode the bike, it ran great no issues whatsoever with the setup.

However a more aggressive test ride and the wheel kissed the filter box ,making a hole in it.

Apparently my measurements were off ,mainly due to the fact I designed most of it looking at the images than measuring on the bike itself. As the bike was at my home town and printer at my workplace I got restless and decided to go ahead.
At least I know the setup works.

Plan C is in works.

**remya** · 03-18-2021, 07:03 PM

wow this is so helpful

**curse** · 01-09-2022, 02:50 PM

This update is for the 2 people still following the thread

Well as mentioned in my previous post the air filter assy had failed.
So started from scratch and made a new one ,this time smaller than the previous one.
Air filter is the component/part where I had to work again and again to make it work,.
Largely due to space constraint and changing the initial idea of using a K&N to paper filter.

Printed a new box with PET-G material this time and used Hero 150cc airfilter.

There are no calculations done in making this box .I don’t know what calculations to be done anyway.
But it works ,motorcycle runs fine across all rpm range, with a loud intake growl. (nothing to silence/dampen the intake sound here)

**curse** · 01-09-2022, 05:29 PM

Fenders-

There were many ideas for fenders. Plastic ones, one from xpulse or Impulse on front.
The chrome plated ones of CD100. I even brought a set.
Finally found a RE front fender ins scrap , It had a big dent at one end rest of it was good as new.
RE fenders are huge,thick and well painted. Plus the one I found was already silver.
I was able to make both fenders using just one of RE.
Lot of cutting and grinding.

I had procured xpulse headlamp long time back , made some 3 printed brackets for mounting.
They are not permanent ,will be replaced with metal ones or reinforced with metal plate.

I had to cut the original coupler on xpulse light and solder one from scrap harness to match the OE Karizma coupler.
The tail lamp was purchased from Amazon. I welded the bracket directly to Hoop.

Finally rode it off road last week.
The rake angle felt high at first but got used to it immediately. The motorcycle is very light and wants to slip away on acceleration, the flat seat doesn’t help. Performed very well on bit of off-road I tried.
Impulse forks and Xpulse monoshock has made the ride very plush and comfortable.
Still lot of work still remains like need to change the handle bar to xpulse one .Original is too narrow,will need risers to mount the xpulse bar as it is low.
Nearing completion.

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Karizma Scrambler-ish Build

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