Stroker built with ATC parts

[WILL_S]

Hi
Been lurking here for ages and using all the cool info to help me build a stroker motor
Thought i would throw up a few pics of a motor build now i have finished it.
The plan was to build a 170cc, but one of the barrels had a issue so i went back to a more reliable 150cc for now.

It started with scoring a nos helm and son atc110 58mm stroker crank.

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/58mmstrokerbuild008.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/58mmstrokerbuild008.jpg.html)

Then i started playing around with different piston combos in the 55mm size for a 138cc using 110 and 125 barrels

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/strokerpistons007.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/strokerpistons007.jpg.html)

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/strokerpistons009.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/strokerpistons009.jpg.html)

But i want bigger power so two 61mm barrels were knocked up to take a couple of different pistons

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-21180453.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-21180453.jpg.html)

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-21165429.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-21165429.jpg.html)

This one below is going on a stock 49.5mm stroke
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-21165446.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-21165446.jpg.html)

A 90 roller cam was used to work out how to turn a 125 cam into a roller

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/2014-09-03154523.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/2014-09-03154523.jpg.html)

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/2014-11-05170127.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/2014-11-05170127.jpg.html)

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/2014-11-05170006.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/2014-11-05170006.jpg.html)

Cases bored

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-24151313.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-24151313.jpg.html)

I have to confess this motor isn't going into a trike,if i had more time iwould love to build a little 70 with a bombed motor.

To be cont.....

[HairyJR]

Looks like a great project, question I have is what boring tool was used to bore cases? Looks like a hole saw. :wondering

"HJ" 222311 :beer

[WILL_S]

Looks like a great project, question I have is what boring tool was used to bore cases? Looks like a hole saw. :wondering

"HJ" 222311 :beer

Um yes holesaw :crazy: .You can't just fire it up am bang it in,there is a technique .I have done about 5 sets of cases this way from 110 to take 125 barrel right up to the 61mm big bores.I have built a few tools for working on these motors but a case borer is on the too do list.

Cases bored for 61mm
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/Turkeycases.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/Turkeycases.jpg.html)

Valve spring compressor

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/2014-04-26105514.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/2014-04-26105514.jpg.html)

Piston holder for machining
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/PISTON%20JIG_1.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/PISTON%20JIG_1.jpg.html)

[WILL_S]

Had a issue with the crank being 10mm to wide for my application,something to do with a pullstart pushing the flywheel out.
Made a spacer plate to space the stator cover,from what i have read you blokes normally space the barrel for strokers:cool:.No dual range for me and also running 12v with ign pickup at the flywheel.That's atc125 crank in the pics with the spacer.

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/20150819_165516.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/20150819_165516.jpg.html)
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/20150819_164735.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/20150819_164735.jpg.html)
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/STATOR%20PLATE%20MOUNTED_1.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/STATOR%20PLATE%20MOUNTED_1.jpg.html)
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/STATOR%20SPACER%20PLATED%20MOUNTED_1.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/STATOR%20SPACER%20PLATED%20MOUNTED_1.jpg.html)

[WILL_S]

Then the shifter won't clear,easy fix without cutting and extending shifter shaft.

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/OFFSET%20SHIFTER%20PARTS.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/OFFSET%20SHIFTER%20PARTS.jpg.html)
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/OFFSET%20SHIFTER%20MOCK%20UP.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/OFFSET%20SHIFTER%20MOCK%20UP.jpg.html)
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/OFFSET%20SHIFTER%20MOUNTED.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/OFFSET%20SHIFTER%20MOUNTED.jpg.html)

[WILL_S]

Bottom end sorted.
The top end i think might interest any old schoolers who want build 110 strokers or big bores.
The first combo was with a gy6 61mm forged piston for 170cc,more time is needed to sort a few things on that,piston to deck height is right with no spacer plate if you use a ct110 barrel and atc125 head.
I needed another motor quick so i took a atc125 barrel and bored it to 57mm then decked it back to 110 height, more was taken off the top of the barrel than the bottom.The oil gallery gets recut.A standard cam chain and no spacer required.

61mm
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/stroker%20mock%20up%20crank%20piston.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/stroker%20mock%20up%20crank%20piston.jpg.html)

57mm
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/CT110%20%20%2055MM%20ATC125%20BORED%2057MM.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/CT110%20%20%2055MM%20ATC125%20BORED%2057MM.jpg.htm l)
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/WALL%20THICKNESS%20125%2057MM.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/WALL%20THICKNESS%20125%2057MM.jpg.html)

Valves won't hit so no extra clearance was required on the piston.Had to drill some oil holes in it.

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/VALVE%20CLEARANCING.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/VALVE%20CLEARANCING.jpg.html)
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/Oil%20holes%2057mm.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/Oil%20holes%2057mm.jpg.html)

[YTZ drew]

Is that a Trail 90 with 2 rear wheels in the background, or an optical confusion on my part? Either way, cool project! I like your piston holder for the lathe chuck, very clever!

[Joseph Farrow]

Excellent Work!
Where did you get your larger sleeve?

[ironchop]

Awesome build, great thread. Subscribed.

Sent from my Z998 using Tapatalk

[WILL_S]

Is that a Trail 90 with 2 rear wheels in the background, or an optical confusion on my part? Either way, cool project! I like your piston holder for the lathe chuck, very clever!

Another project trail 110 converted to a fatcat.

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/th_20150210_095315.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/20150210_095315.jpg.html)

[WILL_S]

Excellent Work!
Where did you get your larger sleeve?

FPM

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-21170709.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/2014-10-21170709.jpg.html)

[oscarmayer]

Nice. You look like me 2 years ago messing with China motors for my son's racing.


Sent from my iPhone using Tapatalk

[Daddio]

Bottom end sorted.
The top end i think might interest any old schoolers who want build 110 strokers or big bores.
The first combo was with a gy6 61mm forged piston for 170cc,more time is needed to sort a few things on that,piston to deck height is right with no spacer plate if you use a ct110 barrel and atc125 head.
I needed another motor quick so i took a atc125 barrel and bored it to 57mm then decked it back to 110 height, more was taken off the top of the barrel than the bottom.The oil gallery gets recut.A standard cam chain and no spacer required.

61mm
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/stroker%20mock%20up%20crank%20piston.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/stroker%20mock%20up%20crank%20piston.jpg.html)

57mm
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/CT110%20%20%2055MM%20ATC125%20BORED%2057MM.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/CT110%20%20%2055MM%20ATC125%20BORED%2057MM.jpg.htm l)
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/WALL%20THICKNESS%20125%2057MM.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/WALL%20THICKNESS%20125%2057MM.jpg.html)

Valves won't hit so no extra clearance was required on the piston.Had to drill some oil holes in it.

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/VALVE%20CLEARANCING.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/VALVE%20CLEARANCING.jpg.html)
http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/RALLYE%20POSTIE%20BUILD/Oil%20holes%2057mm.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/RALLYE%20POSTIE%20BUILD/Oil%20holes%2057mm.jpg.html)

So................., how did this turn out? Curious because I'm getting ready to start building a couple stroker engines. :naughty:

[WILL_S]

So................., how did this turn out? Curious because I'm getting ready to start building a couple stroker engines. :naughty:

Turned out great.
10000+km on it now and getting stronger,that stroker crank must be loosening up :naughty:
Got some bits coming to build 125 cranks into 58+ strokers, will probably be used in my new build with 185/200 top end

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/CTRFXLXR/20160303_145546_resized.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/CTRFXLXR/20160303_145546_resized.jpg.html)

[atcmatt]

Where in Aus are you Will?

[WILL_S]

Where in Aus are you Will?

North of brisbane

[atcmatt]

Sunny Queensland huh. Any dune riding up that way?

[WILL_S]

Sunny Queensland huh. Any dune riding up that way?
Was when i was kid up north qld

[HairyJR]

........Got some bits coming to build 125 cranks into 58+ strokers, will probably be used in my new build with 185/200 top end

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/CTRFXLXR/20160303_145546_resized.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/CTRFXLXR/20160303_145546_resized.jpg.html)

This could be a interesting project, please do post additional information and pic's as you progress.

"HJ" 229952 :beer

[big specht]

From what I heard the kawaski "Honda/Kawasaki hybrid" top end makes as much power as that will with out that much work. But that is just what I heard cause I was thinking of trying that too. I'm not trying to be a nagitive nancy cause I still think it would be cool to do.

[Daddio]

From what I heard the kawaski "Honda/Kawasaki hybrid" top end makes as much power as that will with out that much work. But that is just what I heard cause I was thinking of trying that too. I'm not trying to be a nagitive nancy cause I still think it would be cool to do.
What top end is used on that hybrid?

[WILL_S]

From what I heard the kawaski "Honda/Kawasaki hybrid" top end makes as much power as that will with out that much work. But that is just what I heard cause I was thinking of trying that too. I'm not trying to be a nagitive nancy cause I still think it would be cool to do.
Keen to hear about this too.
All the top end swaps i know about require studs to be moved ,case welding/boring and sorting out cam chain/tensioner .

[big specht]

What top end is used on that hybrid?

The same top end that is on turbo's big motor. I think it a klx style top end

[WILL_S]

http://i218.photobucket.com/albums/cc280/WickedWill_01/BIKE/CTRFXLXR/20160413_160441.jpg (http://s218.photobucket.com/user/WickedWill_01/media/BIKE/CTRFXLXR/20160413_160441.jpg.html)

[oscarmayer]

You know, instead of jacking with cast cylinders that are heavy and hold heat in, you can go to an alloy one. Much lighter, dissipates heat way better and they come in various sizes.
Www.tboltusa.com has them for sale. Check them out.


Sent from my iPhone using Tapatalk

[WILL_S]

You know, instead of jacking with cast cylinders that are heavy and hold heat in, you can go to an alloy one. Much lighter, dissipates heat way better and they come in various sizes.
Www.tboltusa.com has them for sale. Check them out.


Sent from my iPhone using Tapatalk

Are you talking about the atc 90/110/125 stud spacing ?
Or the monster above

[oscarmayer]

the ones where you show the cast iron stock cylinder instead of the alloy ones.
I took a 70cc bottom end, dropped in a 125 crank and rod setup, then added a 52mm long cylinder and finally ordered a 54mm piston. took the piston and cylinder to bored to fit the piston, then height checked the cylinder, half the time I had to have them shave off (1.5-2mm total) the bottom and top and this would bring the piston to perfect spec height. when done, I had a 143cc engine with 14-15:1 compression, big ass cam, and large valves. those little motors would scream!! the trans would bust. I would swap the top end over to a new bottom end and off we went again!
good times where those days. the sad, the 2-strokes would leave us standing still..... hard to compete against a race ready 70cc 2-stroke with a 140cc 4-stroke. they had over double the power and performance. we tried gearing and everything we could only to finally realize we had to change to a 2-stroke. so I swapped to a KX65 with an Athena 82cc BB setup, all ported. ran awesome tons of power, but the quad was too small. so we went to what we run now. Yamaha Raptor 125 converted to YZ85 with 90cc BB setup. so much faster, better and smoother than anything before!!!

[WILL_S]

the ones where you show the cast iron stock cylinder instead of the alloy ones.
I took a 70cc bottom end, dropped in a 125 crank and rod setup, then added a 52mm long cylinder and finally ordered a 54mm piston. took the piston and cylinder to bored to fit the piston, then height checked the cylinder, half the time I had to have them shave off (1.5-2mm total) the bottom and top and this would bring the piston to perfect spec height. when done, I had a 143cc engine with 14-15:1 compression, big ass cam, and large valves. those little motors would scream!! the trans would bust. I would swap the top end over to a new bottom end and off we went again!
good times where those days. the sad, the 2-strokes would leave us standing still..... hard to compete against a race ready 70cc 2-stroke with a 140cc 4-stroke. they had over double the power and performance. we tried gearing and everything we could only to finally realize we had to change to a 2-stroke. so I swapped to a KX65 with an Athena 82cc BB setup, all ported. ran awesome tons of power, but the quad was too small. so we went to what we run now. Yamaha Raptor 125 converted to YZ85 with 90cc BB setup. so much faster, better and smoother than anything before!!!

Cool build
Easier with 70 cases as the china stuff stud pattern is the same.
With the 90/110/125 trike stuff different pattern.

[oscarmayer]

they actually have some stuff now that uses the 90/110/125 pattern, you have to measure the stud hole pattern, then the cylinder height, (bottom deck to top deck) and finally the bore. some of the larger names like GPx and piranha use that pattern even some of the Lifan stuff does as well.

talk to t-bolt www.tboltusa.com Vince knows his trailprotrailprotrailprotrailpro. he an help you for sure. the cheapo Chinese uses the old 70 pattern, but the nicer Chinese stuff use the bigger pattern. i have a larger cylinder and head assembly. if you measure your stud pattern and get back to me, maybe we can work some deals out. ;)