g3ssexy
Active Member
It seems like all the small (sub 200cc) 2 stroke machines end up here, so i figured i'd post mine here as well, even if i feel that it's a cafe. Not too much to say about it. Bought it for way too much money about a year ago without really researching it at all. At the time, small 2 strokes were hard to find in my area, so i snatched it up. I have very little money in this bike, and it shows. Compared to 99% of all other builds on this site that is. What can you do when you're broke though.
But onto the pics:
The first day
Wanted the seat to be as low as possible, so cut everything off the frame.
After making a foam mold and fiberglassing a seat pan, i decided i wanted something metal, so i came up with this.
Bent the actual seat pan.
All welded up
Didn't like how square the seat pan was, so rounded it off a bit.
I then powdercoated it (along with the tank, after doing some dent filling with jb weld).
Tank and seat powdercoated and back on bike.
Figured i might as well powdercoat some other stuff while i was at it anyway, so took off the side covers and prepped them for powder.
After they were done cooling off.
Decided to make a laser cut acrylic magneto cover as i have access to a laser cutter. I also polished the raised lettering.
Installed them back onto the bike. I had also powder coated the kick start and shift levers.
About a week ago i got a job at an indoor motorcycle junk yard. So i got my hands on a complete G4 with a recently honed top end and wiseco piston which i had read swaps right on. I took the top end off the G3 and was ready to do the swap. The G4 / kv100 cylinder is a 5 port aluminium cylinder at 100cc and 11.5hp where as the stock G3 cylinder is a cast iron 3 port at 90cc at 10hp stock. Needless to say, it's not a direct swap. While the cylinder studs line up just fine, the transfers are not the same size/shape. And also, the small end of the con rod is bigger on the G4. Now i MAYBE could have ported the bottom end to match the transfers (not sure there was enough material) and swapped the rod, but i figured i'd just wait to find a good 5 speed 100cc kawi donor engine. I think we might even have one laying around at work. I could have swapped the entire engine from the G4 onto the G3, but it's a 10 speed and i'm sure i can dig up a good condition 5 speed soon.
Needless to say, while i had the G3 top end off, i decided to blast and paint it.
The stock rear shocks were extremely rusty and very small. I'm not a big guy, i'm only about 140lbs, but the tire would sometimes hit the seat pan (now much lower than stock) so i dug up some shocks from work and threw them on. Much better.
My boss had me part out the G4, and keep whatever i wanted off it. So i took the forks and triple tree (the stock forks had a non adjustable triple tree, and i didn't really like their style.) They swapped on just fine. Only problem is they were a few inches longer than the stock forks. Not a big deal as i could just raise the tubes in the triple trees. But then they interfered with the handle bars. The plan is to find or make some 30mm clip ons so i can put the forks wherever i want them. So i ditched the stock fork ears and threw on some from a kx100 that are adjustable.
That's it for now. I just took that last pic today after my first WOT ride of the year. It's still pretty cold here. Future plans include possibly a different front wheel with a better brake. Clip ons, And at some point a 100cc motor swap with some porting. Maybe even a pipe if i can figure out mounting it around the kick start and center and side stands. I was also fortunate enough to be given a vintage quarter race fairing from work. It's slightly damaged, but i'll either try to repair it and use it, or try to vacuum form a new one using the vintage one as a mold.
But onto the pics:
The first day
Wanted the seat to be as low as possible, so cut everything off the frame.
After making a foam mold and fiberglassing a seat pan, i decided i wanted something metal, so i came up with this.
Bent the actual seat pan.
All welded up
Didn't like how square the seat pan was, so rounded it off a bit.
I then powdercoated it (along with the tank, after doing some dent filling with jb weld).
Tank and seat powdercoated and back on bike.
Figured i might as well powdercoat some other stuff while i was at it anyway, so took off the side covers and prepped them for powder.
After they were done cooling off.
Decided to make a laser cut acrylic magneto cover as i have access to a laser cutter. I also polished the raised lettering.
Installed them back onto the bike. I had also powder coated the kick start and shift levers.
About a week ago i got a job at an indoor motorcycle junk yard. So i got my hands on a complete G4 with a recently honed top end and wiseco piston which i had read swaps right on. I took the top end off the G3 and was ready to do the swap. The G4 / kv100 cylinder is a 5 port aluminium cylinder at 100cc and 11.5hp where as the stock G3 cylinder is a cast iron 3 port at 90cc at 10hp stock. Needless to say, it's not a direct swap. While the cylinder studs line up just fine, the transfers are not the same size/shape. And also, the small end of the con rod is bigger on the G4. Now i MAYBE could have ported the bottom end to match the transfers (not sure there was enough material) and swapped the rod, but i figured i'd just wait to find a good 5 speed 100cc kawi donor engine. I think we might even have one laying around at work. I could have swapped the entire engine from the G4 onto the G3, but it's a 10 speed and i'm sure i can dig up a good condition 5 speed soon.
Needless to say, while i had the G3 top end off, i decided to blast and paint it.
The stock rear shocks were extremely rusty and very small. I'm not a big guy, i'm only about 140lbs, but the tire would sometimes hit the seat pan (now much lower than stock) so i dug up some shocks from work and threw them on. Much better.
My boss had me part out the G4, and keep whatever i wanted off it. So i took the forks and triple tree (the stock forks had a non adjustable triple tree, and i didn't really like their style.) They swapped on just fine. Only problem is they were a few inches longer than the stock forks. Not a big deal as i could just raise the tubes in the triple trees. But then they interfered with the handle bars. The plan is to find or make some 30mm clip ons so i can put the forks wherever i want them. So i ditched the stock fork ears and threw on some from a kx100 that are adjustable.
That's it for now. I just took that last pic today after my first WOT ride of the year. It's still pretty cold here. Future plans include possibly a different front wheel with a better brake. Clip ons, And at some point a 100cc motor swap with some porting. Maybe even a pipe if i can figure out mounting it around the kick start and center and side stands. I was also fortunate enough to be given a vintage quarter race fairing from work. It's slightly damaged, but i'll either try to repair it and use it, or try to vacuum form a new one using the vintage one as a mold.