EGLI frame, TR1 engine, build from scratch

50gary

Under the Limelight
Wow, one of my DTT favorites comes back! Great job all around. It's encouraging to hear how well it handles and brakes. Well done vintage style bikes still have a chance. You said you'd run it a Spa in the vintage enduro races. Did that happen? A video would be fun to see and hear the bike.
Cheers, 50gary
 

loekm

TR1 racer is starting to look like a bike!
Hey Gary,

Spa didn't happen... The event became an official FIM championship and is WAY more expensive than it was.... You can not take part without a racing licence... So it will not happen in the near future. I'm going to the event to assist a team in pitstops, good fun!

I hope to participate in Oschersleben this fall. Also a 3 hour race for amateurs. www.classicendurance.com

I shot a video of a small testdrive long ago, it's not running as good as it is now, and the clutch wasn't working ok..... but you get the point. No actual footage of tracktime as the gopro didn't work.... stupid thing.

https://youtu.be/C6EEDRZ5JeQ

Best regards,

Loek

B
 

themotoworks

Been Around the Block
what is the thickness on that large diameter tubing and is the material chromoly? I'm trying to design a similar frame but can't find chromoly tubing like that
 

loekm

TR1 racer is starting to look like a bike!
Well maybe Yamaha had something like it in mind when disigning the TR1 :D It has some "race pedigree" It was sure against the mainstream of that era...

Whatever! I like the engine and it works quite good for me :)

And as we're replying ;) hereby a small update:

The bike has seen quite some track time last season. Had a lot of fun and the bike performed better than expected:
2dt3c52.jpg


Time for some serious upgrades over winter! A pair of dellorto PHM40's were installed and a set of custom rotors

CAD of rotor:
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Rotor in real life:
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Rotor and bracket on wheel:
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Dellorto's:
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So I was ready and psyched for a new season of trackdays :) Power went up from 55Hp or so to 65Hp at the wheel and torque was almost 80Nm at the wheel as well!

And then all went wrong on the first trackday of the season...... :-[ Bad wheather, wet track, rider mistake at the end of straight, to much rear brake, whoop, crash......





Not to much damage, at least no structural damage. new parts needed:
- fairing
- master brake cylinder + handle
- throttle
- brake line

and some small stuf

Also the aluminium tank got punctured... and a footstep needed some serious repair. So the bike was disassembled, new stuff ordered and old stuf and I'm putting it together... hope to be ready for a trackday in the near future.

Best regards,

Loek
 

50gary

Under the Limelight
Loek, so good to hear from you with the update. Every step of the way your work is professional, the brake rotor is outstanding. 10bhp wow a 15% increase! One of my favorite builds ever on DTT, plus it's a track bike, well done.
Cheers, 50gary
 

loekm

TR1 racer is starting to look like a bike!
Good evening!

It's been a while to say the least;) Someone reminded me that this thread still existed and was not exactly "up to date". So I thought to give it a once in a while update. Quite a lot happened to the bike since this last post 4 years ago. Short story and some pictures off course:)

As the bike was some sort of finished it got some track time in 2017, some updates over winter 2016/2017. Crash on the first trackday, quite some damage and the season was almost done when the bike got fixed. End of 2017 season it was back in action and I really enjoyed riding it again.

Winter 2017/2018 nothing big in terms of upgrades, just looking forward of riding it again on track for a new season without breaking or crashing it. All the upgrades for 2017 were hardly tested, so that was the goal for 2018. And that worked out great! I ran 5 trackdays without any major problem. My laptimes increased bit by bit over the season and at the end of 2018 the totally standard fork reached it's limit, it was jumping all over the place. So that was the major plan for winter 2018/2019.

Upgraded the fork internals over winter with new bushings, seals, dustcovers, endcaps, oil and linear springs. And got some new tires. Still roadlegal tires, but more sporty than the previous ones. I was really looking forward to the next season.
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The first weekend of 2019 was at a new track for me, Oschersleben Germany. The bike felt superquick and stable, the fork and tire upgrades did their magic:cool: Nice track by the way!
Off to the next weekend at my "home" track Zolder, Belgium to see what could be done in terms of laptimes. And HellYess did the simple upgrades deliver. 6 seconds of the laptimes, superhappy with that. I was running midfield in the second quickest group in between all the modern stuff:D.

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Did 2 more trackdays and had the idea that I was scratching the limits with gearing and lean angle. I never thought that would EVER happen when I started the build... So 2019 was a very problem free season, only small repair was the oil seal on the outgoing shaft of the gearbox. The bike developed some sort of automatic chain oiling system:rolleyes: Small fix.

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And the bike was still in a "naked" state of finish. No paint on the frame, bare aluminium seat and tank, still bare fiberglass fairing that sort of things. The plan was to really finish it once it was tested (back in 2015) but that never happened, after a very successful season 2019, that finish was the plan for winter 2019/2020:)

So winter 2019/2020 was going to be a big one in terms of maintenance and whole appearance of the bike. Dismantled the bike and started work. First on the engine, checked it all over and upgraded the oil pump to a XV1100 one, at the end of season before the bike was running quite hot. Changed the shift linkage to GP-shifting and raised the pegs by 20mm or so.
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After that I had to fix a very small leak on the fuel tank, vibration caused the tank to leak before so no big deal and I welded it a few times before. Well not this time:eek: At the first weld the tank literally exploded of the workbench.

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Still don't understand why it went wrong.... But the tank was damaged way beyond repair:( cry for a while and make plans for a new and better fitting fuel tank. I was lucky to walk away completely unharmed I guess.

Also made a second silencer to fit. At some tracks you are allowed to make a bit more noise, so a really light and shortened GSXR-1000 silencer was a nice solution. Cheap as chips and it saved a massive 5Kg's or so.

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And some pictures of the new fuel tank construction off course;)

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End of first part....
 

loekm

TR1 racer is starting to look like a bike!
Start of second....

All this work was not really the plan so my schedule was tight to get it running in time for the 2020 season..... still not the finish I wanted :( But as most of you may have noticed, some sort of virus got in the way of pretty much the whole 2020 season.
Deadlines were not relevant anymore, the bike was far from finished and there was no goal to work towards anymore. Big dip in motivation....

After a few weeks got back at it and looked over all the plans for the lost 2020 season. This was April 2020.

Would the engine hold up another season?
Was the fork-upgrade going to support the quicker riding?
Did I need lighter wheels?
Is all the time spent on this bike still worth it?
Why is it still not finished?

All sorts of questions raised and after some thoughts I decided to go for it once more. There were no plans for any track time whatsoever for the whole season. And when the occasion would appear I could always use the street SV650 for some track duty.

Bam, decision was made. Going all out on an engine build was the next step. The bike was in pieces anyway and THIS was The chance to build a stronger engine for the bike. Parts and plans were in stock for a long time, but never worked out in details.

I wanted to do as much of the engine work myself, I always liked other topics of engine build with loads of details and machine time:) And never got time to try it myself. That was about to change big time.

Plan:
Balanced XV1100 crank and conrods with new small-end bushings
Bored and re-sleeved BT1100 cylinders
Bored crankcases to adapt the BT1100 cylinders
100mm Porsche pistons compression ratio +/- 10,5:1
XV1100 heads adapted to the Porsche pistons and CR
New 48mm 2-1-2 exhaust
Adjustable camshaft wheels
Copper base and head gaskets
And so on...
And so on....

The story of the engine build is WAY to long to write down in this single post, but some random pictures will do the trick I hope. It almost took me 15 months to research, think and build the engine as planned and "finish" the bike. Quite some experiments and unknowns went into the build to say the least. But after a lot of ups and downs the engine was in one piece and it even started without exploding on the first go:D:D

So after summer I was working towards a deadline again to get it running and on track for the first time since fall 2019. On 23rd of September 2021 that happened at the most awesome track I have ever driven on, Spa Francorchamps. Almost exactly 10 years after I started the project this was an absolute highlite. The bike worked, didn't break down and drove better than ever before. Looking forward to the next season of RIDING the bike;) instead of building or fixing it over and over....

First the result:
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And Eau rouge towards Radillon on Spa Francorchamps:


And some random pictures of the engine build and bike finish:

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And a small clip:

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Gave the exhaust valves some extra clearance on the Porsche pistons:
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And finally in one peace!
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That was the engine. Bore of 100mm and stroke of 75mm make this Tr1 engine 1177cc.... NICE! At the sme time I started working on some Honda CBR600f3 forks and the frame was of to powdercoat.

End of second part....
 

loekm

TR1 racer is starting to look like a bike!
Start of third...

The new fork in bits:
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One of the first starts:

Starting the thing was a nightmare.... Way to much compression for the weak starter motor. A new starter motor didn't do the job as well. Push start didn't work in 3rd gear down a small slope, but that's always difficult with a fresh engine.
Finally a pair of old fashioned rollers under the driven wheel of a car did the job:D It started right away and sound is nice if you ask me;)
Small test ride on the industrial area near the workshop was the next big thing.

My fellow classic bike builder would give it a try. This was the first drive under the power of the new engine.

After this testride it was finishing the bike for Spa, loads of small things with the electrical wiring, checking if everything is mounted right and tight, that sort of stuff.
The day at Spa was brilliant, the 2021 season only had this one trackday, but it felt like victory. Really looking forward to the 2022 season of riding the bike. I always keep a list of things to do on the bike. Before Spa it was empty off course, the bike was finished. But now after a few weeks not working on the bike, the list starts to grow;) Only small things that need refining or tweaking. But there's a long fall, winter and spring before the next season starts to work on them.

Maybe for the next update in 2022!

Best regards,

Loek
 

JAGspeed

Been Around the Block
DTT BOTM WINNER
Wow this bike is amazing! Glad to see the updates. Was a real inspiration on my XV920R build. Makes me what to do more to my motor now.
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
That is awesome. I would love to know more about the Porsche pistons.
Have you done the cam bearing upgrade. Just finished it off on my Xv1100, was a quick job.
 

loekm

TR1 racer is starting to look like a bike!
@JAGspeed:
Nice! I checked your build and it's a bit on another level in terms of finish:) Engine work is really nice to do, so go for it! but take the time and think twice or even more about what to do. One choice or decision can lead to a whole lot more difficult choices to make. A lot of yamaha XV parts can be mixed and matched so that makes it a bit easier, even BT1100 or XVS1100 parts could be thrown in the mix. I was able to do 95% of the work myself, that's a big part of the hobby. When you have someone else do the work on the engine it's gonna be $$$$. Only boring and honing the new sleeves to spec when they were press fitted in the cylinders was done by an engine building shop.
What it all delivered.... I don't know yet, have to put the bike on the dyno. Was it worth it?? HellYess, learnt a lot and enjoyed the work. Am I going to do it again?? HellNo, way to much work if it's THE engine that should be in the bike. When it's going to be a spare engine, it's a different story. I have enough parts on the shelves to build a spare engine now, so that's maybe going to happen somewhere in the future.

@Brodie:
Yes, the cam bearing is now a roller bearing. And the cam wheels are adjustable as well, although they need to be dialed in, as is the whole engine. The Porsche pistons are from a 911 (993) 3.6L with a bore of 100mm. I had a set of 6 for next to nothing from a local Porsche specialist. They only did 1000 miles or so in the engine before that was upgraded to 3,8L.
So those became my starting point for the build but NOTHING is a standard fit on these things. Only good thing on these is they have the same height above the wrist-pin (deck height??) as the standard Yamaha XV1100 pistons. That was what made them attractive to me and why they were chosen. And Porsche pistons in your Yamaha engine sounds cool to me!! Also important:p
 

ridesolo

Grattoir de cul professionnel
DTT SUPPORTER
DTT BOTM WINNER
Very happy to see your post! A while back I thought about this build and wondered what happened to you.
 

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