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DIY cross bike

Many people dream of a cross motorcycle, because it gives people unprecedented freedom of movement. Unlike most sportbikes and urban models, such a motorcycle is able to move quickly enough outside of good roads, without threatening its owner with a fall and injuries. At the same time, the cross bike is much easier to manage than the enduro and other heavy types of equipment, also adapted for off-road driving. However, many simply can not afford a high-quality motorcycle, because cheap models of real sports SUVs with two wheels are practically not found on the Russian market. Therefore, you should learn how to make a cross bike with your own hands – this will help to save a lot of money and adapt the resulting equipment to your needs.

Home-made cross-country motorcycle

Selection and preparation
As a basis for a cross-country motorcycle, you can choose a used bike of a small class – it is best to choose models with an engine displacement in the range of 125-350 cubic centimeters. The best option would be a road “Japanese” at the age of 12-15 years with a well-preserved engine and a whole frame. In addition, you can even choose a Soviet motorcycle – for example, “Sunrise” or “Minsk”. He will not miss the stars from the sky at sports competitions, however, he will allow you to get a lot of pleasure from off-road adventures.

Cross bike based on Minsk

The motorcycle will have to be disassembled – you must remove all units from it, leaving only the frame. It is better to sort out the motor, transmission and drive components by diagnosing possible malfunctions and eliminating them before the assembly begins. The frame and tank of the future cross-country motorcycle should be cleaned of paint, then coated with putty and applied a new coating in accordance with your wishes. After such preparation, the selection of components and the gradual assembly can begin.

Parts selection
First of all, you need to pay attention to the wheels of the future cross-country motorcycle, since they will be the main burden. It is better to immediately abandon the use of alloy wheels, since they will not be able to adequately absorb strong shocks, which will lead to their rapid deformation. The best option is to buy ready-made wheels based on knitting needles. The budget way to get wheels for a cross-country motorcycle is to buy rims and self-install spokes of the required length. There is no need to think a lot about the size of the wheels and reinvent the wheel, as the sport adopted the standard – 120 / 70-17 in front and 160 / 60-17 in the back.

Particular attention should be paid to wheels.

If you want to make a cross bike from Minsk, you will have to tinker with reworking the rear suspension under a monoshock. It is much easier to turn to a disassembly and pick up a fork of the appropriate size from a 125 cc Japanese motorcycle. It remains only to choose the shock absorber itself – in this case, it is better to choose the right model according to the mass of the vehicle itself and its rider, and then perform adjustment after assembly. Remember that the stroke of the rear wheel of a cross-country motorcycle should be 200–280 mm – based on this value, the components of the rear suspension are selected.

Next, you should take care of the front suspension, which is subject to the highest requirements. Unfortunately, compromising cost-effective options in this case will not work, so it’s better to buy a fork from the cross bike assembly. You can not look at the performance of shock absorbers and the presence of high-quality oil in them – some components of the plug can be changed during operation. For a cross-country motorcycle, the ability to fine-tune the front suspension is very important, so pay attention to the integrity of the tuning mechanisms. The fork travel should be approximately similar to that of the rear monoshock.

Minsk with removed units

For safety reasons, it is worth taking care of installing other brake mechanisms that will allow you to effectively slow down the cross bike if necessary. The best option is to purchase a special sports kit, consisting of other discs, calipers, hoses and fasteners. However, buying it can be quite an expensive pleasure, so you can also purchase used brake mechanisms from a larger motorcycle, which will provide quick deceleration without the slightest problem. If there are drum brakes on a future cross-country motorcycle, you will either have to completely redo the wheels, or put up with the mediocre efficiency of their work, slightly improving deceleration due to the fine adjustment of the pads.

The last thing you need to take care of is the frame. After acquiring all of the above components to create a cross-country motorcycle, you will see that the standard mounting points need to be finalized. Try to use the standard places to fix certain parts as much as possible, without resorting to welding if possible.

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