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Kerm's Sachs Madass 160 [message #301835] Wed, 04 March 2020 21:09 Go to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Bought on a whim although have been looking for about 12 months and these things kept drawing me in for their funkiness and simplicity

https://i.imgur.com/pLPgEyj.jpg

https://i.imgur.com/MwihzCv.jpg

God knows if I'll ride it much but its something to tinker with as the evening grow longer and I had a sneaking suspicion it would fit in the Mondeo's boot to get it home which it did....just...with front wheel off & unfortunately I somehow managed to snap all 4 indicator stalks during the trip home Laugh
Re: Kermit's Next Project Bike is.... [message #301837 is a reply to message #301835] Thu, 05 March 2020 07:52 Go to previous messageGo to next message
Tomthumb is currently offline  Tomthumb   United Kingdom
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(6) Moto1 GP Racer
will this help
https://www.manualslib.com/manual/1195707/Sachs-Bikes-Madass .html?page=2#manual
Re: Kermit's Next Project Bike is.... [message #301838 is a reply to message #301837] Thu, 05 March 2020 08:41 Go to previous messageGo to next message
Gearbox is currently offline  Gearbox   Netherlands
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(15) Kenny Roberts
That bench grinder makes it look very small Grin
Re: Kermit's Next Project Bike is.... [message #301839 is a reply to message #301835] Thu, 05 March 2020 09:01 Go to previous messageGo to next message
Kakugo is currently offline  Kakugo   Italy
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(19) John Surtees
I think those are made in Malaysia, right? think
The engine looks a whole lot like a Chinese clone of a C90 or another older Honda design. Spare parts should be cheap and easy to find on eBay.

As an aside a used Honda Zoomer is €2,500, provided you can find one, and I am yet to see a used Super Cub around. Not that I'd buy either because insuring them is actually more expensive than insuring the CB1300. eek
Re: Kermit's Next Project Bike is.... [message #301844 is a reply to message #301839] Thu, 05 March 2020 15:41 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
I think they're designed in Germany but made in China, just like iPhones 'designed in California, made in China'. I suspect some of the auxiliary parts aren't up to scratch but where there's room for improvement, there's enjoyable tinkering to be had in the garage Grin

This one is fitted with a 160cc engine so might just be able to break the speed limit and iirc its a 4 speed gearbox but its odd in that it appears to be N-1-2-3-4 rather than 1-N-2-3-4

I haven't decided yet how much of an overhaul I'm going to do on it as essentially its working ok except I did manage to break all 4 indicator stalks transporting it home so thats the minimum I need to do but off the top my my head here's a list of parts I'll probably replace

New Brake Master Cylinder + Clutch (might try get modern sporty adjustable type) although I could simply respray the old one + new levers
4 x Indicators (LED) about same size as ones hanging off it
K&N type air filter - existing one is ok'ish but possibly not 100% sound
Stainless Steel Allen Bolts + washers + nuts (were applicable) all round on none stressed parts (eg not brake disc bolts)
New clocks possibly - current oem unit turns on (just) but seems to be lacking functions and speed pickup (from magnet on front brake rotar) not working. Tempted by this


Place your bets as to whether it'll only be partly dismantled to replace parts as and when I get them or a full strip down as I don't know yet myself although in the past when I've got a new project bike I've tended to have it broke down to component parts within 48 hours but its a bit chilly in the garage for that right now but doesn't look a big job on this naughty

Re: Kermit's Next Project Bike is.... [message #301856 is a reply to message #301837] Sat, 07 March 2020 17:58 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Tomthumb wrote on Thu, 05 March 2020 07:52
will this help
https://www.manualslib.com/manual/1195707/Sachs-Bikes-Madass .html?page=2#manual
Thanks Tom, I've grabbed that and an owners manual.

I might need a better manual as there's more wires that I anticipated but I'll see how I get on before committing to buying anything assuming a Cylmer/Haynes exists.
Re: Kermit's Next Project Bike is.... [message #301857 is a reply to message #301856] Sat, 07 March 2020 18:03 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Started the day not knowing how much I was going to strip it...

The clocks. The speedo element of this stock clocks isn't working. Might just be wires or the sensor pickup and will consider further down the path whether to get working or replace with something nicer that includes tacho/gear indicator etc. The fake carbon stick on stuff will have to go. I like carbon but not fake stuff.
https://i.imgur.com/nrS4u1V.jpg

Bodged the Abba stand to give me a decent chance of working on it
https://i.imgur.com/nNh2q6R.jpg

Almost forgot to drain the fuel till it started leaking Blush
https://i.imgur.com/7thsxAd.jpg

I think you can tell where this is headed now.....
https://i.imgur.com/7I5Dbjv.jpg
Re: Kermit's Next Project Bike is.... [message #301858 is a reply to message #301857] Sat, 07 March 2020 18:12 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Engine out
https://i.imgur.com/PCOoHhg.jpg

Carb for info as likely I'll get a rebuild kit for it
https://i.imgur.com/G9Q9DF9.jpg

Casing look a little rough but gave a few areas a quick going over with a soft wire brush after I took this pic and it seems to come up quite well....it dirty but not heavily corroded. I'm not sure if there's any other good alternatives to improve the finish other than wire brush....don't fancy polishing it
https://i.imgur.com/0i09ot3.jpg

Engine Markings (for reference if I need parts)
https://i.imgur.com/jKZlfzm.jpg

https://i.imgur.com/O5nbTg6.jpg

Box of bits to clean/spray/check
https://i.imgur.com/MC7B1eT.jpg

Auxiliary parts
https://i.imgur.com/ZwXvVfn.jpg

The frame - Not sure what to do with this. Finish is ok with just a few chips here and there and could probably get a touch up pen of ebay or Halfords but half of me is thinking to power coat it along with other bits like the upper/lower yokes, fork lowers and battery box + other black parts although that would probably add +£200 to costs

Alternatively I could keep frame stock, touch it up, then get the Hammerite Satin Black out for the black parts

Thoughts on keep stock, powder coat some/all etc?
https://i.imgur.com/pcLaLBn.jpg


Re: Kermit's Next Project Bike is.... [message #301859 is a reply to message #301857] Sat, 07 March 2020 18:14 Go to previous messageGo to next message
Tomthumb is currently offline  Tomthumb   United Kingdom
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(6) Moto1 GP Racer
Whoa , stick with it Si, whats the battery like , usually a poor one wont light the panel?
Re: Kermit's Next Project Bike is.... [message #301860 is a reply to message #301859] Sat, 07 March 2020 18:24 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Battery is a Yuasa. The seller gave me a reasonable charger for it but I'll stick it on my optimate and let that check its condition.

I'm not even 100% sure it has charging circuit working or not as the seller thought it ran off 100% battery race bike style but with the bike not running the horn (see first opening post for that large red/black trumpet thing front/top of engine) struggled to make a sound but when I had it running, the horn worked well so I think the charging circuit is probably ok although I think I'll replace the horn with a smaller/normal horn....less weight Grin
Re: Kermit's Next Project Bike is.... [message #301861 is a reply to message #301860] Sat, 07 March 2020 18:45 Go to previous messageGo to next message
Tomthumb is currently offline  Tomthumb   United Kingdom
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(6) Moto1 GP Racer
Not sure if this might help it's off a sach's madass 50cc but 4 gear
/forum/index.php?t=getfile&id=22521&private=0
  • Attachment: mad ass.JPG
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Re: Kerm's Sachs Madass 160 [message #301862 is a reply to message #301835] Sat, 07 March 2020 19:13 Go to previous messageGo to next message
Kakugo is currently offline  Kakugo   Italy
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(19) John Surtees
"Gearshift is prohibited unless accelerator is loosed".
So much for the myth of Chinese education being the world's finest. Wink

I think your engine is Yin Xiang YX160 and I hope there's nothing wrong with it because, albeit spare parts are easily available, I won't touch another Chinese engine no matter how much money I am paid. No Finger

If the engine isn't painted (it surely doesn't look like it but I am down with rheumatic fever and I have more drugs in my body than usual) you can try Dursol with a microfiber cloth. Dursol is grandaddy of the standard Autosol Metal Polish and can be used on most metals. Pretty impressive stuff for basically being 50's vintage. Thumbs Up

The horn has issues because it drains more amps (perhaps even far more) than the battery could provide at the time. It's a good recipe for melting the horn switch. Wink Weigh if it's cheaper to buy a standard horn or fit a 4P mini relay.

Keep the frame stock, no point throwing £200+ into it. Every pound you save is a pound you can use to buy a new GPU or just some fish and chips.

Oh yeah, and buy a large diameter funnel. Wink
Re: Kerm's Sachs Madass 160 [message #301873 is a reply to message #301862] Mon, 09 March 2020 19:46 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
The engine is running fine Kak and yes I was 99% sure it was Chinese but as you say parts are plentiful and cheap and looks a lot easier to work on than my 929 engine Laugh

I'm taking your advise & keeping costs down by painting it myself but not the main frame as thats fine and I don't trust myself to spray large bits. Have bought a silver touch up pen on a best guess eyes vs colour on cap basis by taking seat unit into Halfords and settled on a generic silver pen (not Honda, BMW etc) which I've tested a spot on the seat that had a 2mm chip, let it dry and it looks an almost perfect match so will do the rest of the main frame touch up in due course.

Started cleaning up the parts to be sprayed first in engine degreaser, then soapy water and once dry a final wipe over with 99% alcohol
https://i.imgur.com/fVgVPTB.jpg

First coat of etch primer. I ditched my usual Hammerite Smooth Satin Black as I'm spraying the yokes and Hammerite doesn't work on alloy without a special primer that my preferred motor factor place didn't have so went Simonez with their Etch Primer + Tough Coat Satin Black
https://i.imgur.com/xZg59WD.jpg

https://i.imgur.com/CMxMtoz.jpg

First coat of Satin Black on
https://i.imgur.com/vpL2FNg.jpg

https://i.imgur.com/38iTc2M.jpg

Second coat is now on and will give it at least a few days to dry

I cleaned the loom at the same time as degreasing the metal parts as it had some old sticky electric tape and a bit dirty. Its now fairly clean and ready for a bit of a tidy up re-wrapping with new tape in places I'd removed the old tape
https://i.imgur.com/LhgSZia.jpg


Re: Kerm's Sachs Madass 160 [message #301874 is a reply to message #301873] Mon, 09 March 2020 20:08 Go to previous messageGo to next message
Tomthumb is currently offline  Tomthumb   United Kingdom
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(6) Moto1 GP Racer
Looking good matey Thumbs Up
Re: Kerm's Sachs Madass 160 [message #301881 is a reply to message #301874] Tue, 10 March 2020 07:53 Go to previous messageGo to next message
Yorkie is currently offline  Yorkie   United Kingdom
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(8) Moto2 GP Racer
Now why did everyone know, when you bought it, that it would end up in 100s of bits and looking like new at the end of the day Grin Grin
Re: Kerm's Sachs Madass 160 [message #301888 is a reply to message #301881] Wed, 11 March 2020 21:00 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Wish I'd taken more pictures of the battery box area.....I can't even figure out where the regulator attaches Sad
Re: Kerm's Sachs Madass 160 [message #301892 is a reply to message #301888] Thu, 12 March 2020 06:47 Go to previous messageGo to next message
Tomthumb is currently offline  Tomthumb   United Kingdom
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(6) Moto1 GP Racer
Kermit wrote on Wed, 11 March 2020 21:00
Wish I'd taken more pictures of the battery box area.....I can't even figure out where the regulator attaches Sad
Couldn't find a picture anywhere but found another resource
https://www.ooracing.com/sachs-madass.html
Re: Kerm's Sachs Madass 160 [message #301894 is a reply to message #301892] Thu, 12 March 2020 10:26 Go to previous messageGo to next message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Thanks but ooracing is one site I've already been looking at regarding any parts I might need. I guess I could call them to ask advice although I'll probably be able to figure it out as spent 1/2hr or so in the garage last night mounting the back box (that supports the swingarm/engine) that the look has to feed through and sort of figured out some of the routing but then got frustrated when I had to undo some routing and remove the backbox but suspect with more time I should be be able to figure it out although still confused where that damn regulator* should be mounted as I can find no bolt holes that match the size within the right distance that its connector on the loom will allow.

*its about the size of normal Japanese regulator with 2 holes and fins
Re: Kerm's Sachs Madass 160 [message #301897 is a reply to message #301894] Thu, 12 March 2020 16:20 Go to previous messageGo to next message
Tomthumb is currently offline  Tomthumb   United Kingdom
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(6) Moto1 GP Racer
Could it be mounted on the battery box , would have thought it would have to be away from weather but somewhere it wont over heat think
Re: Kerm's Sachs Madass 160 [message #301898 is a reply to message #301897] Thu, 12 March 2020 21:35 Go to previous messageGo to previous message
Kermit is currently offline  Kermit   United Kingdom
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(22) Giacomo Agostini
Got to be around battery box somewhere, within 6-8" I reckon given its wire length from other wires I know go in there but looking at this pic just now, I can't see the connector for the regulator as iirc that has 2x3 connector block with at leats 2 yellow wires so now I'm think the regulator must be forward of this point on the other side of the box which is where the coil is

This is where most of the wires go including starter solenoid/relay (not required as kick start only), flasher relay, CDI. Battery sits in bottom half of this box.

Wish I'd taken a pic before removing everything Doh

https://i.imgur.com/18MnbwM.jpg

This is the loom. The sections that go to the back end boxed in red (green box I think must be starter motors wires which were already taped up)

https://i.imgur.com/hyRefa9.jpg
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