Monday, May 30, 2011

Motorcycle maintenance and useful tools #3



FasMetal™ 10 HVAC Repair

Tested and proven, as used by proffessionals worldwide.

High strength, aluminium filled epoxy for bonding, patching, filling and sealing.

Used for repairing large and small holes in aluminium and other metal castings; building up metal surfaces, sealing leaks in pipes and tanks, sealing, filling, bonding similar and disimilar metals plus much more!

Aluminum-filled epoxy adhesive conveniently packaged in a 6 1/2 oz (184g) tube with a second tube containing hardener. Enough to do more than just one small job!
  • Bonds to aluminum and other metals, ceramics, woods, concrete or glass  
  • Repairs coils in compressors  
  • Hardens to a rigid bond that can be ground, drilled or tapped  
  • Fills voids or porosity in aluminum castings

This is not a cheap product to just get the job done. It is industrial strength and is used by proffessionals worldwide.

Do it once, do it right!

Available through Trojan Classic Motorcycles.
Part number: TLS0034

Tuesday, May 24, 2011

BMW R65 Cafe Boxer

1984 650cc BMW R65. How much would you expect to pay? Well Martin R. was lucky enough to snap this one up for a case of beer. So there was one thing he had to do... Build a Cafe Racer.

The idea was to keep the mods simple, practical and raw.
A fibre glass seat base was sourced from the US and trimmed here in Australia. The paint was done by a friend and Martin insisted he paint the checkered flag stripes rather than use decals. A slight over spray of white on the edges really gives it that no-nonsense ready for race look.

To get the ball rolling Martin sourced the following parts at Trojan Classic Motorcycles, like a kid in a candy store he went to town.
Ace bars, clubman mirrors, pod filters, tacho and speedo gauges, megaphone mufflers, cateye tailight, heavy duty headlight brackets, MKII indicators...Pure Cafe!

The engine is stock and reliable as hell. It also sounds great. The frame is standard except for the rear section which was extended to take the seat.
Clever black outs, period custom parts, careful planning and the result is a BMW Cafe Racer that looks awesome and built to ride.

Friday, May 6, 2011

Trojan Triton returns to the Barry Sheene Festival of Speed

Last year we raced our Triton at the Barry Sheene Festival of Speed Sydney, Australia and we were back there again this year!
For those who don't know what happened last year, perhaps click here before reading on:

The Triton runs a BMW R50 TLS front hub and these aren't easy brakes to set up. Last year we ran the brakes vertical with the cable pulling from the top in hope that the stopping power would improve. We based this theory on the Triumph 69-70 TLS. We were having to apply the brake at least 100 metres before coming into turns and that was costing us time. Ultimately we would love to fit a magnesium Sealy 4LS set up but they go for around $3000
Ultimately we would love to fit a magnesium Sealy 4LS set up but they go for around $3000.

We re-lined the shoes with racing compound, machined the drum and radius machined the shoes to fit.
The brake plate is now modified to work the shoes horizontal. This is how they would have worked from the factory. Basically like the Triumph 68 TLS, cable pulling from the rear.


We also beefed up the rear brakes and fabricated a fully adjustable brake lever stop/adjuster to gain extra stopping power.

As usual we checked, re-built and set up the carbs, lubed all cables etc. We then re-routed all the breather hoses and added another from the timing cover.

My apologies for the delay on this post but i did actually spend many hours finishing it only to find it wiped off two days later by the boffins at blogger. Apparently they had technical issues and wiped off thousands of posts all over the world. They did promise to return the posts but this did not happen so i'll do my best to continue where i left off.

We were asked by the organisers of the event if we would like to display a trade stand. This would generate interest and also give Trojan Classic Motorcycles an opportunity to show the public what we do. The lads arrived early Saturday morning and did a great job setting everything up.

Rigid frames, custom oil tanks, fenders, handlebars, lights, levers and we made an extra special effort to do our first T-shirt in support of the Trojan Triton!

On display a variety of books, magazines, badges, belt buckles, tools, mufflers and much more!

The response was overwhealming, the crowds loved it and the boys were kept busy talking to people and looking after VIP customers (see below).

Meanwhile, in the pits, the Trojan Triton is being prepped for it's first race. Our rider Rick is fired up and ready to go. At the grid and they're off. The Triton looks good and Rick pulls third place. Upon return Rick tells me the bike is not running smooth through the revs. He's confidant we can do better. The tools are out and we get ready to diagnose. Looks to be carb issues. For the next 2 hours we do our best to resolve the problems. The next race is called and we get the bike off to a good start but Rick pulls in with a flooding right side carb and a hairline fractured fuel tank. Our race for the day is over so we now prepare for Sundays races.

This event is getting bigger every year and there were some outstanding examples of classic race bikes competing in different classes and events. Here is a selection that caught our eye but there were many more.

Sunday and the tank is repaired (we used Devcon metal putty, it's the best solution when welding is not an option). Carbs were cleaned and checked, ignition also double checked and we're ready to go again.

A vast improvement as Rick manages to place 2nd. Excellent result but we have missed one race in the competition and have one more to go. To gain a third place in the overall comp we must achieve second in our last race.

We desperately need to source the problem of our poor rev range and in doing so we see that our left intake hose has developed a hairline fracture. To top it off we have an intermitent spark on our right plug. I notice th HT pick-up is also fractured. Could this be it? I quickly jump in the old Chrysler and head to the local speed shop. I find a GM radiator hose. It will have to do. As for the pick-up, i had no choice but to head to our shop and grab a spare. In doing so, i managed to break my tailshaft uni joint. Can you believe it? I crawl the car back to the shop knowing that i'm doing horrific damage but we have a race to finish. Nick is on his way to pick me up and we get back to the pits with half an hour to get the Triton ready.

We are now at full working speed. Even Ricks' son lends a hand. I didn't notice but the little guy was watching me pull the carbs apart and now was handing me each part in reverse sequential assembly. How's that for observant? I look up at Rick and we both just smile. Like clock work the bike is now ready for it's final race. It sounds good but i know it's not 100%. No time, we just have to keep our fingers crossed and hope for the best.

Nervous? Excited? Anxious? Hell yes. The race starts and Rick is really pushing the Triton. He guides the machine through the corners and makes it seem effortless. And he does it again! Second place which means we place third for our class in this competition. High fives all round and Rick is back in the pits after an amazing ride.

Fastest lap time in our class was 1.57.
Our fastest was 2.00. (last year our fastest was 1.55)
We placed 3rd in our class. If we just entered and finished the race we missed, we would have had enough points to claim 2nd place hands down. That's racing!!

Once again it's been an awesome year with a result that reflects our efforts. Racing demands hard work, concentration, dedication and a good team effort. I believe we achieved this.

A big thanks to Rick K. for once again riding the Triton and giving it hell, Filip and Tore for helping out with the trade stand, TFMW Lucas J, Mick for helping out in the pits, Junk MC mag Billy Wizz, Frank 'Mr Tig' for helping get the workshop jobs done to allow us to race, Minas and Harry for your ongoing support, Emil at Industrial Strength Australia who always plugs Trojan Classic MC, Tim at Faster Pussycat, Gabby, Big Al, everyone who bought a Trojan Triton support T-shirt (those who haven't can redeem themselves, we still have some left!), our families for putting up with our shananigans, my bro Nick for his incredible effort to make this all happen, all our customers and those who have supported Trojan Classic Motorcycles.

We will be back next year but for now we have a lot of work to do. We plan on completely strippping down the Triton for a rebuild.
See you there next year!

Sunday, May 1, 2011

Trojan Pit-Starter. (Roller Starter)

    =======Trojan Pit-Starter =======>>>

                                      ‘A portable, safe and easy way to start motorcycles’

Ideal for the astute motorcycle enthusiast, the TPS allows for quick and safe starting of motorcycles, both touring and race bikes, in the workshop or at the track.

TPS duplicates the action of push-starting a bike by spinning the rear wheel up to a speed of 40kph. On releasing the clutch with the bike in gear, the engine is induced to start.


1. Set up the TPS on a suitable area of level ground behind the motorcycle.

2. Lower the ramp and position the starting switch in a suitable position on the side that suits you.

3. Plug the TPS into an appropriate 240 V power source.

4. Back the motorcycle onto the TPS ensuring the rear wheel is square to the rollers, central between the side-plates and that the front wheel is directly in line.

5. Sit astride the motorcycle and apply the front brake.

6. Select second gear (or the gear you would use if push-starting).

7. Some 4 stroke bikes require pulling back over compression

8. Turn on the motorcycle ignition switch, fuel levers, choke etc as appropriate.

9. Pull in the clutch lever.

10. Sit firmly on the seat and operate the TPS operating switch with the heel.

11. With the rear wheel spinning, let out the clutch to start the engine.

12. Release the TPS operating switch.

13. With the engine running, select neutral or pull in the clutch lever.

14. Push the motorcycle off the TPS.

Unit Dimensions:
43 cm (L) x 43 cm (W) x 14 cm (H)

Weight: 13.8 kg

Trojan Classic Motorcycles Pty Ltd
4/ 117 Punchbowl Road,

Belfield, NSW 2191

Telephone: (02) 9759 6990