Need Help for CAFE RACER build!

Hi guys,
I hope this post gets posted (the earlier few didn't). If it does, then this is going to be my first post here. Straight to the point. I am building a CAFE RACER based on the Hero Honda CD 100. I am in the middle of the build. With almost NO experience in bike building I have come up here for HELP! I have never built a bike or have any automobile degree or a diploma. This is just out of pure interest. I am just stuck on the following few things which I am not able to figure out on myself.
1) The front forks and Disc break setup.
2) The rear sets issue.
3) The swing arm issue.
4) The wheels.

1) I am going to replace my front forks with that of FZ F1 or Bajaj Dominor. My question is that do I need to use the front disc setup of the bike from which I am going to borrow the forks? Or I can use just any disc set up. I dont want to use the disc set up of dominor in case I am using the forks of dominor because it is too heavy considering the engine is a 100cc CD-100 engine.

2) I want to change the foot controls higher backwards. I am 6" tall and I am going to use Clip-ON handlebars. So, with the changed ergonomincs, I need to change the foot position. How do I do that? Is there any universal rear sets available in India?

3) I want some views on extending the swing arm. What else do I need to look after?

4) I want to replace its stock wheels which has drum setup both at front and rear. I want to install 19" front disc and 19"rear drum setup from RE Bullet Electra.

Thank you

Re: Need Help for CAFE RACER build!

Topic Approved.

@Loner_wolf Please don't create additional threads, this will confuse all. I'm deleting the previous threads as this has more queries than the previous ones.
Also, work on "Editing" your post if you want to add something. or just add a new reply.

There are rear sets available readily for few bikes, although I don't imagine any for the CD 100. Avoid bolting it to the Swingarm nut, it may appear an easy way out, but its not worth the risk.

One choice is that you repurpose the pillion's footpeg as rider's, since cafe racers are mostly single seat.

There are various adjustable choices for single toe gear lever, but none of them is this long, so you may need to modify one to fit it.

On the other side, brake pedal will also have to be adjusted, but there you might encounter issues as the silencer might come in the way.
One choice is to use stunters' like approach and have an additional brake lever at your right hand.


Either ways, I find the approach to use the pillion's footpeg better in terms of reliability, although they might not help with overall handling.

Re: Need Help for CAFE RACER build!

Thank you so much for the reply. I was thinking about using the pillon foot pegs. Are the linkage rods readily available in the market?

Re: Need Help for CAFE RACER build!

As far as I'm aware, no bike has a ready linkage rod this long in market.
Harleys have some, but they're expensive, plus they work in an inverted way (i.e. its like a cruiser not like a sports/nakedbike, the gear lever is positioned ahead of the engine shaft, not the other way round).

You may have to get one made from "Engineering Shops", the ones who custom make parts and they have all sorts of lathe, grind, etc. machines.
Choose a common steel rod and tell them to make bolt-able grooves according to the old, shorter rod. See the image below:-



The rod in middle of the two rubber covers, that's the rod you must replace, after measuring it properly on bike.


Once you get the particular rod made, then you can fit in on an existing gear lever setup, like from Pulsar 220, or RTR 180. Just replace the rod with the longer one, that's it.

You'll also have to have a slot welded to fit in the gear lever's foot-side's actuator. See the image below:-



This actuator's hole is something which will be below the footpeg most probably, and it can be made by using a small custom made part which attaches with the footpeg. Again, engineering shop can help.

Once you're done with rear sets, you can proceed further towards other steps...

Re: Need Help for CAFE RACER build!

Thanks Samarth once again. That was all the info I needed. [emoji4]

Will be updating soon on the advances. I am very busy these days with office as well as my exams.

Re: My first DIY amateur Cafe Racer project!

Samarth, by the way what are your views on the wheels? Say, if I use the wheels from the RE bullet electra then can I use the front disc set-up from any other bike? I don't need such a huge disc as that of the RE's. Its jus going to be 100cc and I want to cut off on weights as much as possible

Inviting all those who have a knowledge of Motorcycle front forks!

CAN ANYONE ANSWER THE FOLLOWING QUESTIONS ON THE MOTORCYCLE FRONT FORKs

1. How does the fork length matter? I mean, I have seen bikes with taller fork size been reduced by affixing the triple trees a lot below the original position making the forks stick out.

2. What are those nuts/bolts called that hold the forks to the triple trees? And where do I find these beautiful bolts we see on the internet here in India?

3. How do I get the triple trees to match my forks? Do I need to purchase them as an assembly or those have to be custom made? if they are custom made, who makes these here in India?

4. If I have no knowledge about motorcycle forks, but can but and bolt, can I replace a motorcycle myself or is there any critical technical procedure involved?

5. What would be your advice for someone like me who has almost no technical idea on motorcycle forks and who have started building his own cafe racer at home (not a workshop) and who has no one else to guide him?

Thank you.

Performance upgrades for 100 cc motorcycle Ignition unit!

Hello everyone,
I am very glad to be a member here. The information available here is enormous.

The topic today I want to discuss is about upgrading stock CDI, Ignition coil, Spark plug wires & Spark plugs.

I have some doubts/querries on the following:
1. I am replacing my stock spark plug on my HH CD 100 engine to NGK Iridium CR6HIX spark plugs. Are there solid terminal nuts available in india to fit the solid type Spark plug wire?

2. I was also planning to replace my existing spark plug cable with NGK Racing wires. I did a blunder and ordered a solid type wire instead of a threaded terminal version. I hope it'll get replaced or refunded.

3. I want to change the ignition coil with a performance ignition coil and I have no ideas where or what to look for. Any suggestions on what would suit my need?

4. Also, I want to replace my stock CDI with a performance CDI, where do I get one which matches all the above?

Thank you!

Re: Performance upgrades for 100 cc motorcycle Ignition unit!

Topic Approved, moved to Help Section, merged to existing topic.


Please continue posting in the same thread that was originally opened for the Cafe Racer purpose.
Otherwise, Xbhpians will get confused on your actual objective while performing these changes... As all of them have not followed your posts since the beginning.
And why post this in Universal Threads section? We post only new topics in Universal Thread section, in which there is information, not questions.

I'm merging your topics together regarding the Cafe Racer... so that members can track what you're doing & help accordingly.

Please understand Xbhp forums in detail, by visiting various sections and searching for already posted info.

----consecutive posts auto-merged-----

Its not necessary that with a Bullet wheel, you'll be able to fit in another disc brake setup.

That's because the caliper has to be attached to the front fork, and their mounting points differ. For example, in Pulsar 180 UG3 or 150 of any generation, the disk brake is about 240mm, but you can NOT fit the disc brake from Pulsar 220 (which is 260mm disc), just because the forks and calipers are different.

Best move would be to look for a 100cc-125cc from Bajaj, which has a disc brake setup from company. If you don't want white alloys, search for such a setup in TVS/ Hero motocorp.

Since you're making a cafe racer, white alloy wheels should look good.

Re: Performance upgrades for 100 cc motorcycle Ignition unit!

Thanks a lot for your reply. And sorry for creating new threads. I'm new here and I haven't been able to figure my way out here till now. [emoji1] Moreover, I am using the mobile app XBHP Connect to post. So pardon me!

Coming to the point, what I actually want is bigger wheels that only RE Bullet has 19" at both ends. Also, white alloys would definitely look good but I prefer spokes, preferably 80/100 spokes aftermarket spoke wheels. Can you suggest me something considering this? Isn't there are any other disc setups to fit DOMINAR/FZ F1 forks? (I'm planning to go for the Dominar/FZ F1 forks actually)

Once again thank you!

Re: My first DIY amateur Cafe Racer project!

Received my first parcel among all the caferacer parts I am purchased. Really very happy with the product.[emoji4] [emoji111]

Re: My first DIY amateur Cafe Racer project!

Help needed!!
Can anyone tell me the options to install a steering stem from a different bike in the frame of a different frame? What if, the steering stem shaft is bigger in diameter/length, what are the available options???

Re: My first DIY amateur Cafe Racer project!

Finally after lot of brainstorming for almost a month I ended up swapping the Stock Triple Clamp Shaft of tye HH CD100 to the Yamaha FZ fi Tiple Clamp. and here are the results. However, due to the thicker upper clamp of the FZ, i had to ditch the Star nut on the shaft and have only used the Steering Stem nut. hope it works! [emoji4]

Re: My first DIY amateur Cafe Racer project!

Keep it up bro.... Good work