my latest buy, 2x Yamaha Chappy 80cc 2 strokes, and build/modify thread

[my67xr]

hey gents and femmes,

some of you may have seen pics of my 1984 Yamaha IT200L,
well, keeping true to the Yamaha man i am, i have added 2 more bikes to my collection.
im into things that are slightly different than most people, and modifying, i just cant help myself....:b_grind:
i kind of wanted a Z50 but sorry, they are getting a bit too common,
im glad ive now found these.

i have just picked up a couple of bikes this morning,:banana:
i plan to do one up and register it, the other will be used up on our farm for a while
both have compliance plates, one even has a rego plate, both could be rego'ed quite easy.

the old owner is going to get me a box of spares he has stored away too,
including some New Old Stock (NOS) parts

they are both Yamaha Chappys, model LB80II A, 80's (72cc), auto, 2 strokes
one is a '75 the other is a '77 model.
these bikes weren't massly produced, the 2x are built 2 years apart, yet the serial numbers are only 800 away from each other!
Chappy's get used for anything, golf buggy towing, farm use, pamphlet deliverys and allsorts.
they have a full auto gearbox, and also have a Drive / Neutral / Low setting,
and can climb almost anything in low (single speed low)
one has even had an electronic ignition conversion from a ride on mower too!
top speed on the speedo is 80 Mph

the motors are based on the early GT80 / MX80 / YZ80, and a lot of motor/gearbox parts are interchangeable.
i have plans to hot at least one of them up....:scooter:
mods like - a YZ expansion chamber, ported barrel, bigger flatslide carb, change the gearing etc etc

both bikes have only done around 11,000km's and 12,000km's since new.
parts for the resto etc are easily available on ebay etc

they are still available around the world new too, in different countries.
there are a quite a few video's on youtube featuring them, i will add some too.

as i have so much on the go, this will be a slowly built thread
i will update things as i go....
and if anyone has any parts i could use, just let me know

cheers, craig

some pics;

 

[bulldog93]

Nice find. Look good for their age too.

ore of a postie rather then a Z50.. Close to a dax but not quite..

Can't wait to see the build progress

 

[FMX_22]

what little gems look like there in good condition keep us posted

 

[MiniFighter]

Nice find mate, what sorta $$ these going for?

Cant wait to see the rebuilds in full swing!

 

[The_GDFP]

Sweet find! Might find them to have more in common with the Fizzy and other 50/55/60/80/100cc horizontals that Yamaha pumped out by the millions in the 60's and 70's. Rarer 4-speed engine would be best if you plan to increase/narrow the RPM range and hotrod it. eBay is teeming with parts, if you can't get them there. I can re-ship at actual cost if a US seller won't post to AU.

The usual YamaDinger tricks work. Turn down oil pump, mill head a mm. Free and add a bunch of low to mid snap.

PW80 looks real similar, for a CDI, 4 speed swap.

 

[my67xr]

cheers guys,

i had a bit of a play around yesterday,
i tidied up the '77 with the tan seat,
i straightened the handle bars up, repaired the headlight brackets, and aligned the indicators,
replaced a couple of globes, front indicators work now, replaced brake/tail globe and the headlight globe.
replaced the battery, fixed the brake light switches,
removed the oil feed to the pump, washed out the fuel tank and lines.
cleaned out the carby, added fresh fuel. degreased the whole thing and pressure cleaned it.
i removed the rear pannier, the frame to mount it was only hose clamped on.

i gave it a kick over, and it started second kick, with the choke on.
it revs quite well, responsive. it took a bit to clear the oil from the cases and exhaust, smoked for a while.

i might get a chance to do a bit more today.

and thanks for the offer on shipping too, Terry, i appreciated it.

cheers, craig

 

[my67xr]

forgot to add,
i paid $300 for the pair of bikes, a pretty fair price i thought.

 

[my67xr]

a couple more pics,
i am cleaning up the vinyl seat atm, i used some general purpose thinners and a clean rag,
it's coming up nice...you can even notice the gold piping trim at the ends

and the straightened, widened bars, and headlight bucket repaired for the time being

 

[my67xr]

i have tuned the chappy a little more, the one with the tan seat.
it had a bit of top end noise so i took the head/barrel off.
piston is pretty worn, ring is needing replacement, bore needs a rebore etc.
the big end bearing is shot too, the piston/rod has about 1.5mm slop.
im suprised the piston doesnt hit the head.
this motor is now out of the bike.

i pulled the motor out of the other chappy and degreased the thing,
iremoved the head/barrel and found a newish genuine piston/rings, 4th oversize and a honed barrel, nice
this motor had a leaking case gasket so i made another and bolted it back together.
then resprayed it while it was out.
i refitted it the next day and swapped the stators over etc
the front sproket was shot so i grabbed a new one off a pw80/kx80, even though it was a 12 tooth over the original 15t.
got it started and this motor sounded sweet.
did a couple of laps of the back yard, it makes the old motor look really bad.

i found an old mx80? expansion chamber at the dump for $5, and had a play with it.
first position was a bit hard to setup due to the rear spring etc, would have been polini style
so i revised the position of the expansion chamber and cut it up a bit, also made a custom muffler while i was at it.
first setup

revised setup, i swapped seats too during the exhaust mods.

it has taken a bit of tuning but i think it is fairly close now, jets are 2 or 3 sizes bigger.

sounds like a yz80 now, and pulls even harder than before.
cant wait to take it for a strap now.

 

[my67xr]

just needs some final grinds and tidying up, then a coat of paint
oh yeah the intake piping is now bigger and better filter
and the wheels have been painted silver and the swinarm and stands are now black too.

edit, just saw how blurry the pics are, will get some better ones later

 

[aussie_140]

is that a pro circuit pipe? haha nice build mate i love it

 

[my67xr]

thanks mate,
i couldn't find a Pro Circuit expansion chamber for a Chappy anywhere.
even tried FMF, and DG too, dunno why they dont make them lol

we've been having a bit of fun on it up on the property.
tried teaching my 11 year old to ride on it, and the mother inlaw too......
both ended up on their backsides after pulling huge wheelies, i wish i had it on video.
would have been perfect material for Australias' funniest home videos

i will get some updated shots of the Chappy in a couple of weeks when we go up there next
goes pretty hard, changes from 1st -2nd at 30kmph, and hits powerband at 40kmph
revs hard all the way to 65 kmph top speed.
wife loves burning around on it, and trying to keep it upright in the sand too.

cheers, craig

 

[Chops]

Bit of a grave dig, I've seen one of these locally and it looked to be in great condition.
A old guy was riding it.

 

[my67xr]

not much has happened with the Chappy/s for a while,
we had a bit of fun riding it around on the farm, we tried teaching my 12yo son and mother inlaw to ride it....
neither went too well learning, both had the front wheel up in the air within a few feet, and running behind trying to keep up with it..lol
i will be selling it/them sometime soon it think.



it must be the time for seeing old bikes around.

last night i saw a old bloke parked on the side of the road tuning his faded metallic green ST90 Honda.
i stopped, and went over and spoke to him.
he told me he had just put a set of rings through it, and was taking it for it's first run...... since 1985 !!!!
his father was the original owner, bought it new, and had passed away and left it to him in his will.
the guy had given the motor a freshen up, took it down for the rego inspection, and registered it.
he said it cost more to register it than it cost brand new back in the day, lol
he laughed, and mentioned that tuning the bike, was like he was reliving his youth again..
nice bloke

 

[my67xr]

the time has come to sell the Chappys.
i have been tidying up the running bike, it was resprayed in enamel at some stage,
and was approximately 20 shades darker than what it originally was.
i went through my paint and found some paint that is very close to the original Chappy Red
it's Spartan Supercryll Brilliant Red.

so far over the last couple of days i have rubbed off the enamel,
and blended the original paint into parts where it was back to metal etc, and etch primed it
i'm up to the last sections now, from the centre of the seat base and back.
you can see how much darker it was in the second to last pic, above the expansion chamber/silencer.
the headlight bucket and the fork leg headlight brackets came up nice.

i have also plastic welded the front fender, it had a couple of decent cracks in it, one being 200mm long.
once welded and smoothed off, i have 2 pack bogged it then sanded, etch primed and resprayed it in white.
the engine top cover has also been resprayed.

this morning i took the centre stand off, bare metalled it, and resprayed it in gloss black.
and i have swapped the standard rear shocks with a pair of cleaned up, Honda Postie shocks i had laying around
the original Yamaha shocks have seen better days!!

 

[my67xr]

in the last pic,
under the centre stand you can see the side kickstand, that will be coming off the scooter, get repaired and resprayed then refitted.
when the previous owner had this bike, it was used as his golf buggy, and he towed his golf bag behind it out on the course.
someone had welded a big 4 prong base to the bottom of the stand, so it wouldn't slip on the grass when parked at angles i'm guessing ?
i chopped it off not long after i got the bike.

a few other jobs that need doing are to de-carbon and respray the full exhaust.
respray the front, lower fork legs
remove, clean and respray the rear swingarm and brake rod, and hub support.
respray the rear fender,
clean up, repair and refit the rack off the back
i am also thinking about respraying the front and rear hubs, in satin black while i'm at it too.

 

[ringo]

Very cool build!!!

 

[my67xr]

cheers mate,
doesn't quite compare with the standards of your builds though !
this has been a very low budget bike.

i hope the new owner appreciates the work that's gone into it.
i haven't seen many others that are this clean, most are basket case's.


it's overcast here today, hard to get pics of the colour differences.

 

[my67xr]

just noticed in the first pics at the top of the page,
the Chappy has only done 37 km's since we got it, i'm sure it would have done a lot more than that!

 

[xLOCOx]

ha good work mate, shes looking quite nice atm
you could make your own expansion chamber for her it would look pretty neat....
awesome restore