sudhir222
Motoholic
Since the last couple of months, I have been posting over FB, updates on the revival of my FlyinMachine back to the streets but never posted a thread here, so here it is.
The bike is a Machismo 500, 2008 model, clocked 48000 kms. It had hardly seen any long rides since the entry of the D390 since last Jan and was suffering from multiple issues - erratic running being the most prominent one. Meanwhile, thought of shedding some weight to improve the power-weight equation since that is the best possible performance boost for a bullet.
While the project will certainly take some more time for the entire makeover, here is the current status:
1. I bought a BS33 carb meant for Pulsar 200NS - about 3100 bucks.
Had to remove the accelerator cable holder and install the one from older BS 32 carb. The new one is positioned at too acute an angle and hence cable routing isnt possible.
I have recently installed the Thumper exhaust - good performance and reasonable exhaust note. I dont have the need to grab attention with loud, mind numbing roar and it will be a headache during highway runs anyway so this exhaust is perfect. Also made of aluminum body(reduced weight) - almost all after market exhausts have cheapo chrome on it and start rusting.
Well, this meant I had to re-jet the carb - pilot is now at 17.5 and main is 120.
On Sunday, installed the Bullet 500's inlet flange meant for 33mm carb - got this after pestering the dealer for two months.
There is a tiny shim on which the needle sits and since I wanted to make the mid range richer, inserted the shim below the needle placement. All this because, BS 33's needle doesnt have any notches for adjusting the mixture.
2. Installed TB headlamp, T-stem and the old RD handlebar.
Electra front fender. Still needs to be tweaked for the alignment.
Got all these powder coated - matte black.
3. I did a very stupid purchase - got the old TB headlamp without checking the headlamp socket.
Since the mechanic had installed the headlamp while fitting the repainted forks, I asked him to just install it. Enough of labor paid to him!
Yesterday, after a test rain ride realized that this illumination was shit was wondering why I cannot replace the 35/35W sealed beam with the old Minda assembly from the stock set up. So removed the sealed beam and took out the old reflector/bulb assembly to compare.
Old reflector/H4 bulb socket assembly installed into the TB outer rim.
The dimension is almost same, only difference being the locking clips(refer picture with red circles) used in the stock set up are longer and hence cannot be used in the TB dome. So used just 3 clips from the new assembly to lock the reflector assembly. Fortunately, all of it fitted pretty well without much fuss.
This evening connected it all back and works well and am happy.
Look before the sealed beam change:
Changed the blinkers to stock position:
Few close up of the handlebar arrangement and cable routing:
I feel this lens looks much much elegant!
Items bought but yet to install:
1. C5 cartridge fuse box.
2. C5 handle bar. After trying the stock, RD and low handle bars, I believe the C5's one will be comfortable for touring as well add to the scrambler look. The stock handle is great but looks too tall after the headlamp mod.
To do list:
1. LED blinkers, most likely from KTM - they work great.
2. Round rear fender and super slim scrambler seats. Will retain the split arrangement though - idea is to make the rear seat into a luggage rack cum seat frame.
3. Fabricate frame for the speedometer/ammeter and ignition switch.
4. Aux lighting.
5. Ceat GRIPP tires - front and back.
The bike is running good with crisp throttle response now.
Will keep you all posted whenever updates occur.
Cheers!
The bike is a Machismo 500, 2008 model, clocked 48000 kms. It had hardly seen any long rides since the entry of the D390 since last Jan and was suffering from multiple issues - erratic running being the most prominent one. Meanwhile, thought of shedding some weight to improve the power-weight equation since that is the best possible performance boost for a bullet.
While the project will certainly take some more time for the entire makeover, here is the current status:
1. I bought a BS33 carb meant for Pulsar 200NS - about 3100 bucks.
Had to remove the accelerator cable holder and install the one from older BS 32 carb. The new one is positioned at too acute an angle and hence cable routing isnt possible.
I have recently installed the Thumper exhaust - good performance and reasonable exhaust note. I dont have the need to grab attention with loud, mind numbing roar and it will be a headache during highway runs anyway so this exhaust is perfect. Also made of aluminum body(reduced weight) - almost all after market exhausts have cheapo chrome on it and start rusting.
Well, this meant I had to re-jet the carb - pilot is now at 17.5 and main is 120.
On Sunday, installed the Bullet 500's inlet flange meant for 33mm carb - got this after pestering the dealer for two months.
There is a tiny shim on which the needle sits and since I wanted to make the mid range richer, inserted the shim below the needle placement. All this because, BS 33's needle doesnt have any notches for adjusting the mixture.
2. Installed TB headlamp, T-stem and the old RD handlebar.
Electra front fender. Still needs to be tweaked for the alignment.
Got all these powder coated - matte black.
3. I did a very stupid purchase - got the old TB headlamp without checking the headlamp socket.
Since the mechanic had installed the headlamp while fitting the repainted forks, I asked him to just install it. Enough of labor paid to him!
Yesterday, after a test rain ride realized that this illumination was shit was wondering why I cannot replace the 35/35W sealed beam with the old Minda assembly from the stock set up. So removed the sealed beam and took out the old reflector/bulb assembly to compare.
Old reflector/H4 bulb socket assembly installed into the TB outer rim.
The dimension is almost same, only difference being the locking clips(refer picture with red circles) used in the stock set up are longer and hence cannot be used in the TB dome. So used just 3 clips from the new assembly to lock the reflector assembly. Fortunately, all of it fitted pretty well without much fuss.
This evening connected it all back and works well and am happy.
Look before the sealed beam change:
Changed the blinkers to stock position:
Few close up of the handlebar arrangement and cable routing:
I feel this lens looks much much elegant!
Items bought but yet to install:
1. C5 cartridge fuse box.
2. C5 handle bar. After trying the stock, RD and low handle bars, I believe the C5's one will be comfortable for touring as well add to the scrambler look. The stock handle is great but looks too tall after the headlamp mod.
To do list:
1. LED blinkers, most likely from KTM - they work great.
2. Round rear fender and super slim scrambler seats. Will retain the split arrangement though - idea is to make the rear seat into a luggage rack cum seat frame.
3. Fabricate frame for the speedometer/ammeter and ignition switch.
4. Aux lighting.
5. Ceat GRIPP tires - front and back.
The bike is running good with crisp throttle response now.
Will keep you all posted whenever updates occur.
Cheers!
