So here it is as it arrived. It’s a running bike with 22k on the clock. it’s not as tidy as it looks in the pictures, the paintwork in particular lets it down. It’s a runner, but it had some electrical issues, which were easy to trace, the loom was a mess!
progress on this build will be a little slow as we have summer soon, and a few extended holidays so garage time will be limited. I will be doing some jobs though!
I have now stripped off all the parts that I definitely know I won’t use, and these are being sold to fund some of the build. First little job has been to machine the top yoke and rough some clamps out so I can fit conventional handlebars, to make it easier for me to move it around, and so I can sell the originals.
I am not sure yet on the style this will end up, but it needs to be reasonably easy to ride, no clip ons! I am also going to make a tank in alloy this time, and work is already underway designing and making an English wheel which I am quite excited about.
I took the Multi out yesterday for its first short ride and was REALLY pleased with the way it run on the new ignition and carbs... and that got me thinking... I don't think anyone has done a 996 engine on carbs...(most will say why the hell would you!!) I like the idea! So I have sourced a pair of nice flat slide 48 mm carburettors! Watch this space!
I have decided to give the keihin 48mm CV flatslides a go... these are off a Honda VTR, and apparently they are some of the biggest carbs fitted to a bike... unless you know different of course! they have come up really well...
a little bit of progress, I have made the first manifold out of plate and tube, its came out quite well... I have managed to mount the carb at the same angle it was on the Honda VFR it came off.
I have mounted to other carb, it sits high so I had to cut a panel in the tank to clear it. I may end up making a tank for this build, but for now I will use the original to get it all running
Late August and the weather is terrible… so I have made a start… for a few weeks before we go on holiday anyway no going back now as I have had the angle grinder out on the rear of the frame. I really don't want to use the ST4 tank though so I have managed to find a badly dented Ducati alternative in a breakers, which seems to fit after a bit of under tank surgery!
I was going to try to make a tank, but I really like the 996 one i have picked up cheap...* but its taking quite a bit of work to modify to fit over the carbs.* I have had to cut the bottom out and fabricate a new base.* some of the welding is done, and I thought it best to dye pen the joints as its easier to correct leak on the outside of a joint, rather than inside when its all welded up... good job i did as there were two leaks.* Dye penetration works amazingly well as you can see.
Finished the fabrication on the bottom of the tank, all pressure tested and no leaks!* I have had problems finding a fuel tap big enough...* most are 8 mm but the Honda carbs require 10mm pipe, they were a thirsty beast!* found one in the end...* but I wont be running a reserve.* Also made a couple of short bellmouths to fit under the pod filters.* they were made out of tube, and spun in the lathe to bell the ends out.* to do this you need to soften the alloy first by annealing it.* I have struggled with this in the past as you need to get the temperature right, but if you go too far, it suddenly melts into s a blob!* the answer is simple, a trick picked up from a mate...* scribble on the alloy with a sharpie pen...* *heat until the pen marks disappear, and stop heating! then let it cool. it works a treat!
sometimes you make stuff but are not sure… this is an example. I wanted the front of the bike to be clean looking… so I made this speedometer using a cheap GPS module that will come on automatically when the ignition is on. the holes are for some warning LED’s… not sure if I will use it yet. I am aware that technically its no legal to have a GPS speedo… but…!! Whats peoples opinions on the look?
Also been practising my alloy welding with my new TIG welder to make a battery box for under the tank.
The exhausts are now fabricated, as is the seat, but I may shorten that a bit.. and I am undecided on the moto GP or the mega style of silencer, I guess I have plenty of time to decide.
The seat was made out of insulation foam, and cut and sanded to shape, which is VERY easy to do. its then covered with a few layers of glass mat and resin. I also had the headlight brackets water jet cut, they came out really well!
No updates for a while as we are off on holiday for a few weeks!
They come in several anodized colors, or just plain semi-polished aluminum (which is what I used). Excellent design and build quality. Stainless steel internal siphon tube as well.
Through-hole mounts with about 1/4" standoff on the back side of the tank. O-ring sealed machined aluminum cap.
I sat for a long time in the garage, imagining how I could make the footrests. I knew exactly where they should be as I want the riding position to be “just Right” like my other bike. one important factor was some sort of rubber mounting. the design proved to be difficult, and after mocking some up in plywood, I came to the conclusion it would actually be quite difficult. In the end I have used the footrest assemblies off a Multistarada, which combine all the attributes I wanted, with the bonus they were an easy fit! I have also braced the frame. A considered decision… so many of these bikes break their crankcases. hopefully this will prevent that.
The throttle linkage is also now done… The right throttle action can make the world of difference to how a bike rides. I bought a cheap twist grip and played around with different diameters until it felt right. I will make a replacement now to the correct dimensions.
Sign the weather is getting cooler... I have moved to the other side of the garage, near the radiators!
Nice job on the peg arrangement, very clean. Curious on how and why though. 1st gen Multi pegs is a straight bolt up? How did it change the position from the original ST peg location?
Thanks! I changed the pegs because I want a more upright riding position, the pegs are now a bit lower, and quite a bit further forward. I had an ST4 for a few months, loved the bike, but hated the riding position...
They pretty much bolt on. the crankcases are much the same dimensions. what you cant see is there is a piece of 10mm all-thread that runs from one side to the other, inside the hollow swinging arm pivot. this braces the top and works well, and retains the rubber mounting. I would want to try some first with the standard exhausts though...
Made a couple of items in the last few days... first I have mounted the front mudguard, made some stays out of alloy tube, complete with formed ends to make them look better, and also less prone to cracking.
Also finished off the tank plate and mounted the ignition switch. this took a while as I panel beat it out of some alloy plate into a compound curve. I made a tool to press the raised portion to add a little strength, and make it look a little better. I have mounted it with some 5mm anti vibration rubbers. Of course all will need a polish, but that all comes after the mock up stage!
Took the frame in to my mates factory today to fully weld it… its easier on the big bench, and his gas is a 10th of the cost of my small bottle at home! I noticed the cracks on the underside of the cross over frame tubes, both sides! really glad that I braced it now. I don’t feel its the best designed frame…
well I dye pen tested all the welds on the frame today, all OK apart from the obvious ones...
been stripping the wheels tonight, first I had problems getting the front bearings out as the inner spacer tube is a tight fit and I could not get on edge of the bearing to knock it out, ended up grinding a piece of flat with a tang on... this soon had it our. MUCH harder were the cush rubbers... I simply could not get to the back of them to get them out. I made a split collet in the end and pulled them out with a big socket!
lots of heat does help, but the cush drives are always annoying.
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