Classic Motorcycle Mechanics May 2015

PROJECT ZXR WINS YAMAHA FJ1100 SUCCESS DOWN UNDER

BUYER’S GUIDE

ALL THAT’S BEST IN MODERN CLASSIC MOTORCYCLING ition ed ed t i m t i l a helme 7 X R Arai

ISSUE NO.331 MAY 2015

Knowledge:

Honda SS125 engine strip

Project bike:

Suzuki GT500 Café Racer

PROJECT BIKES: KAWASAKI ZRX1100, YAMAHA YSR50, YAMAHA XS650 TYING DOWN A BIKE ❙ DECALS & GRAPHICS ❙ SETTING UP A WORKSHOP

May 2015 Issue 331 Publisher: Steve Rose, srose@mortons.co.uk Contributors: Mark Williams, Shaun Nielsen, Daryll Young.

Art Editor: Justin Blackamore Reprographics: Simon Duncan Divisional advertising manager: David England, dengland@mortons.co.uk Advertising: Sam Dearie, Lee Buxton sdearie@mortons.co.uk, lbuxton@mortons.co.uk Tel: 01507 524004 Subscription manager: Paul Deacon Circulation manager: Steven O’Hara Marketing manager: Charlotte Park Publishing director: Dan Savage Commercial director: Nigel Hole Associate director: Malc Wheeler Editorial address: CLASSIC MOTORCYCLE MECHANICS MAGAZINE, Media Centre, Morton Way, Horncastle, Lincolnshire LN9 6JR Website: www.classicmechanics.com General enquiries and back issues: Tel: 01507 529529 24 hour answer phone help@classicmagazines.co.uk www.classicmagazines.co.uk Archivist: Jane Skayman jskayman@mortons.co.uk, 01507 529423 Subscription: Full subscription rates (but see page 36 for offer): (12 months 12 issues, inc post and packing) – UK £50.40. Export rates are also available – see page 36 for more details. UK subscriptions are zero-rated for the purposes of Value Added Tax. Distribution: COMAG, Tavistock Road, West Drayton, Middlesex UB7 7QE. Tel: 01895 433600 Subscription agents: CLASSIC MOTORCYCLE MECHANICS MAGAZINE, Media Centre, Morton Way, Horncastle, Lincolnshire LN9 6JR Printed: William Gibbons & Sons, Wolverhampton Published date: CLASSIC MOTORCYCLE MECHANICS MAGAZINE is published on the third Wednesday of every month Next issue: Wednesday, May 20, 2015 Advertising deadline: Monday, May 4, 2015 © Mortons Media Group Ltd. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage retrieval system without prior permission in writing from the publisher. ISSN 0959-0900 CLASSIC MOTORCYCLE MECHANICS magazine takes all responsible steps to ensure advice and technical tips are written by experienced and competent people. We also advise readers to seek further professional advice if they are unsure at any time. Anything technical written by the editor is exempt – he’s rubbish with spanners.

CLASSIC MOTORCYCLE MECHANICS (USPS:729-550) is published monthly

by Mortons Media Group Ltd, PO Box 99, Horncastle, Lincolnshire LN9 6LZ UK. USA subscriptions are $60 per year from Motorsport Publications LLC, 7164 Cty Rd N #441, Bancroft WI 54921. Periodical Postage is paid at Wisconsin Rapids, WI. Postmaster: Send address changes to CLASSIC MOTORCYCLE MECHANICS, Motorsport Publications LLC, 7164 Cty Rd N #441, Bancroft WI 54921. 715572-4595 chris@classicbikebooks.com

What, or who, inspires you?

The question above has really been an underground theme for this issue.

Think of it. Who first inspired you to throw a leg over a motorcycle? Did you reciprocate and mentor someone else to get aboard two wheels? Questions like these abound in this issue. Scoop, pictured above, tells us in his column this month that his dad inspired him to ride. The bike he’s riding is a copy of the replica inspired by one of the greatest racers ever – Eddie Lawson. OK, so it’s a replica of a replica, but I can buy that. Back in 2006 I made my own ‘Steady Eddie’ rep with a crash-damaged Kawasaki ZRX1200. It wasn’t as flash (Dream Machine paint, Ohlins shocks, Renthal bars, Kerker exhaust) but I sure wish I hadn’t sold it.

I’ll do a proper job of it one day.

Having trouble finding a copy of this magazine?

Why not Just Ask your local newsagent to reserve you a copy each month?

ds Bertie Simmon editor

Bertie Simmonds

Joe Dick

Chris Moss

bertie@classicmechanics.com ...RD350R engine and send it to the man below. Then the chassis to NK Racing. Time to shift one’s butt!

editorial@classicmechanics.com Our Joe turns out a stunning performance this month making Scoop look like Eddie Lawson.

editorial@classicmechanics.com This month he’s riding an Africa Twin, next month he main-tests a classic: Honda’s CX500. He owned a few...

Steve Cooper

Mark Haycock

John Nutting

editorial@classicmechanics.com The Flying Tash enjoyed his place in the sun this month. Normally a tiddler fancier he’s enjoyed the Eddie Rep.

editorial@classicmechanics.com Poor Mark - he’s bought a right heap of an XS650. Still, he’s experienced enough so it will come good.

editorial@classicmechanics.com A month off, but he did chat to Bob Trigg for our update on the IDP Moto/CMM Rebooted RD350LC.

Stan Stephens

Andy Westlake

Daryll Young

editorial@classicmechanics.com Our Stan is passing on his skill and knowledge about setting up a workshop this month. Part two.

editorial@classicmechanics.com Andy met a man with a unique collection of small-capacity Hondas.

Marvels in miniature.

editorial@classicmechanics.com The diminutive diva of IDP Moto gives us the lowdown on how project Retro Reboot RD350LC is going.

Don Morley

Paul Berryman

Sam Dearie

editorial@classicmechanics.com Plenty of Don’s shots adorn this mag this month. Check out his shot of Wayne Rainey on page 6.

editorial@classicmechanics.com Well, it’s been all about a Gag this month. A Gag bike. Yamaha’s YSR50, which turns out to be an 80.

editorial@classicmechanics.com This be the man you need to contact to find out how to advertise in this marvellous magazine.

It’s time to package up the...

Just Like Eddie...

Independent publisher since 1885

So, who got me on two wheels? Well, mainly my uncles who always had an attractive lady on the back of their 1970s and 1980s machines.

A school pal Paul Evans (thanks mate) did the rest by letting me ride his Suzuki X1 after lessons. Thank goodness our parents never knew what we got up to on the rugby field of a Friday night. It normally consisted of cider, Suzukis and girls. I’ve since got a few mates onto two wheels and have also got CMM’s talented designer on a bike at the Honda Ron Haslam Race School. I hope he’s hooked! In turn I hope you find something in the mag that inspires you to ride, build, brag or restore.

Lord of the (piston) Rings.

Legendary photographer.

CMM’s toppest snapper

King of the Q&A pages

West Country stringer.

King of Comedy.

Quick Spin spinmaster.

Minister of MIRA.

Retro Reboot-master

Super-duper ad man.

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Contents 06 XRV750 08 HONDA AFRICA TWIN ARCHIVE

The majesty of Wayne Rainey.

The original adventure bike ridden by Mossy.

13

NEWS

Don’t forget to join us at Anglesey in May!

18 CALENDAR

All the places to go in the month of May.

20

FEEDBACK

22

SHOW US YOURS

26

CMM RETRO REBOOT RD350LC

30

Your letters and mails to us – thank you!

More of your marvellous metal. Keep ’em coming.

We keep you up to date with this amazing project.

69

❙ WORKSHOP NEWS

72

❙ Q&A

76

❙ HONDA SS125

Your questions answered.

39

NOSTALGIA

The humble Scottoiler has turned 30.

80

❙ STAN STEPHENS

44

EDDIE LAWSON REPLICA

82

❙ TIE YOUR MOTHER

Steve Cooper throws a leg over a green legend.

Part two sees the engine stripped.

Stan’s wisdom on workshops!

DOWN!

How to secure your machine in shed and van. Apologies to Queen fans.

53 READER’S SPECIAL

87

❙ YAMAHA XS650

56 UP THE CREEK!

92

❙ YAMAHA YSR50 GAG

60 THE MOT

94

❙ KAWASAKI ZRX1100

66 KAWASAKI ZX-8R

98

❙ CAFÉ RACER GT500

110

❙ YAMAHA FJ1100

122

❙ DECALS, VINYLS,

A down under rebuild of a rare V4 Honda.

Our Anitpodean Project ZXR wins at Eastern Creek!

What is it and how can you pass first time?

What if the ZXR/ZX-7R were being built today?

129 NEXT MONTH

Mossy rides the Honda CX500 in June!

Poor Mark Haycock. This is a hound of the basket cases.

BIKE

Paul Berryman’s bought a joke. He’s serious!

HONDA TIDDLERS One unique collection!

Pip returns this month. Hurrah!

Alan Dowds starts the engine rebuild on his ZRX. Engine work begins.

The old big smoothy revealed.

GRAPHICS

How to apply ’em like a pro.

130

❙ COMING CLASSICS

Why the Aprilia RSV1000 Mille is a bargain.

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8 / classic motorcycle mechanics

2000 Honda XRV750

WORDS: CHRIS MOSS

H

onda’s Africa Twin is another bike that conjures up specific memories for me. Back in 1994, I joined a sportbike mag, and did so with thoughts of ripping round the country on big bhp, hi-spec, racereps. But just days into the job I was sent on an errand on one of the twin-pot Hondas.

Deemed back then as a big-trailie (the poncey, pretentious world of ‘adventure’ bikes was still some way off). I treated the prospect of riding the 750 with some disdain. A nose bleed-inducing seat height, skinny tyres with knobbles on ’em and a pathetic 60bhp were just

PHOTOS: MIKE WESTON

some of the numerous discouraging ‘features’ serving to put me right off the bike. I wouldn’t care, it wasn’t long since I’d been earning a living delivering parcels aboard battered old high-mileage sheds. So quite why I was getting a bit snooty about a trip on the Africa Twin, god only knows.

Turns out the 20-odd-mile run was a real education.

What a corker of a bike the 750 was. Super comfy, dead easy to ride, torquey motor were just some of the qualities I quickly listed. By the time I was done, I’d added plenty more. No wonder I’d seen so many of these sorts of bikes whenever I’d whizzed over to Europe. Suddenly the Africa Twin made a load of sense, and made me realise there were more bikes to like than just race-reps.

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Featherweight fliers!

Honda’s history has foundations laid on the more humble, smaller-capacity machine. Terry Brown has a few of them.

WORDS AND PHOTOS: ANDY WESTLAKE

B

y 1977 the Isle of Man TT had been stripped of its world championship status but it didn’t deter the thousands of road race fans who made their annual pilgrimage to the hallowed Island venue that year.

Among them was Terry Brown; a young man who had ridden his TL 125 Honda over 200 miles from his home in South Wales to spectate at his first TT. A smallcapacity off-roader would not be everyone’s choice of machine for a long motorway trip but Terry was not fazed by the ordeal of huge trucks bearing down on him and the TL would be wheeled out again when he repeated the journey in both 1978 and 1979.

Amazingly not only did he survive but four decades on he still owns and rides the same little four-stroke; a bike which now shares garage space with an eclectic collection of seven other Honda lightweights from the 1960s and 1970s.

“When I was a lad there seemed to be bikes everywhere in my home town,” says Terry. “When I was 16 I got myself a 125cc BSA Bantam that I passed my test on and this was quickly followed by a 150cc version from which I learned a lot about the mechanics of motorcycles as it was forever breaking down.

“I would soon be the proud owner of a shiny black C200 Honda: the asking price was £25 but after a bit of negotiation it was mine for £18 and 10 shillings and it didn’t take me very long to find out that compared to 30 / classic motorcycle mechanics

Terry Brown and his collection.

2010

2000

1990

1980

1970

1960

Honda Tiddlers production timeline

C100 1958-1967 C102 1960-1965 C50 1966-1986 C70 1969-1986 C90 1966-1986 C100EX 1986-on Super Cub 50 2007-on Super Cub 110 2009-on Dream 110i 110 2011-on TL 125 1973-1978 CD 175 1969-1979 C200 1964-1967

Not much is cooler than a Cub or two.

SPECIFICATION

Super Cub (Honda 50 in the UK as Triumph carried the name on its 200cc single.)

C100 1958-1967 C50 1966-1986 ENGINE

ohv single-cylinder fourstroke CAPACITY

49cc

BORE & STROKE

40x39mm OUTPUT

4.5bhp @ 9500rpm IGNITION

Flywheel magneto TRANSMISSION

the Bantam the little Honda was like something off another planet.

“Despite only having a 90cc engine it had a decent turn of speed but the most important difference was that whatever the weather it always started first kick, the engine was bulletproof and the only time I had to get the tools out was to treat it to a regular change of oil every 1000 miles.

I used the C200 for many years as my ‘ride to work’ machine, it never let me down and I think it was one of my biggest mistakes when I finally decided to sell it.

“When my father died in 1976 he left me two Lambretta scooters but as I had no interest in them I decided to sell them and bought a brand new TL 125 which I rode to the Isle of Man the following year. With a top speed of around 55mph it was slow going on the motorway to Liverpool and because of its limited range I had to carry some extra fuel in an old Castrol R bottle

but once on the Island it was the perfect bike to get to some of the out-of-the-way vantage points around the TT course via the green lanes and tracks.

“The local farmers were quite happy for us to go anywhere as long as we shut the gates behind us but a policeman in Douglas wasn’t so keen when he spotted me doing a wheelie along the beach one evening and was heard to say ‘when we catch him he’ll be on the next boat back to the mainland’.”

Terry escaped the long arm of the law and rode the TL to the island again in both 1978 – to witness Mike Hailwood’s amazing winning comeback – and also the following year but it would be the last long trip on the little Honda. We now fast forward 32 years where he takes up the story again...

“In the summer of 2010 I was at a show with one of my pals and as we looked at the stunning line-up of

3-speed gearbox with wet semi automatic clutch FRAME

Pressed steel FORKS

Leading link REAR

Swingarm with twin shocks BRAKES

4.3in drums TYRES

2.25 x 17in front and rear WHEELBASE

46.5in

DRY WEIGHT

143lb

FUEL CAPACITY

3 litres

TOP SPEED

43mph

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Tiddler fanatic Scoop rides a hairy-chested big four – the Eddie Lawson Replica – and comes back grinning like a loon.

WORDS: STEVE COOPER PHOTOS: JOE DICK, DON MORLEY

A

s Rob Weed pulls off the covers from his exceptionally tasty and well-crafted Kawasaki my eyes are immediately drawn to the tyres.

Or to be more precise the now hardened crumbs of what was once molten rubber on the outer peripheries.

A thought goes through my mind along the lines of “Oh hell, he isn’t going to expect me to produce something similar surely?” Riding your own bikes at or near to the limit is one thing; getting close to the edge (sic) on someone else’s hard work is an entirely different matter.

Trust me here, you really do not want to be damaging someone’s pride and joy. But, I’m here to do a job so I’d better get myself psyched up ready for the task in hand.

If your reference point was modern sports bikes or classic period Japanese middleweights you might need to do some mental recalibration here. This is one big motor and a substantial amount of running gear. The whole Eddie Lawson Replica thing stems from a point in time when the Japanese motorcycle industry had only just started coming to terms with the concept of proper handling.

At the beginning of their rise to supremacy all of the players had concentrated their focus on power and reliability. Every single yen of R&D funding had been spent on building a sustainable reputation that would generate repeat business. Initially, necessity had been the mother of invention; the various clubman racers offered by the factories had often handled appallingly.

It was only when satellite teams and privateers in Europe, USA and Australasia started to modify factory frames that the missing parts in the jigsaw were finally lowered into place. When the likes of Colin Seeley, Dave Degens in the UK, and numerous others around the world making decent handing frames for 44 / classic motorcycle mechanics

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Next month

HONDA CX500: Mossy on the marvellous Maggot.

SUZUKI X7: One man and the stroker he’s had since new – 36 years!

MIRA FILES: John Nutting and the Yamaha XV1000 TR1.

QUICK SPIN: Chris Moss gets aboard the Honda CB550.

BRILLIANT BROOKLANDS: A look at the magnificent museum shot by Don Morley.

RETRO REBOOT: What if Yamaha turned the original Vmax into a café racer?

PLUS! WORKSHOP: Stan Stephens continues with the V6 RD500LC build, Pip Higham fixes things for feck-all again.

JUNE PROJECT BIKES: Former team-mates Niall Mackenzie and James Whitham return with their Yamaha RD400 and Suzuki X7 project bikes. Scoop is back with his Project Rickuki, and we hope that the Suzuki apprentices are back on with rebuilding the motor on their Suzuki GSX-R1100L. AND LOTS MORE DON’T MISS IT!

ON SALE: MAY 20

All subject to change.

Feel free to complain to the editor (sometimes it’s not his fault!)

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