Details

Bore x stioke

88 x 65.2mm

Capacity

396cc

Bhp

35-36 approx

Dry weight

112kg

Wheelbase

1440mm

Ground clearance 315mm

Seat height

970mm

Front forks

Simons

Rear shock

Fox

Fuel tank

1.3 gallons

600 3tb White
O In the workshop a lot of detail work went on.
Yamaha Szr 660 Skid Plate
O This neat little device was developed to lilt the footrest out ol the way so the kickstart has lull movement.

>Suzuki RMH470

O Above: As with any special, ifs often easier to make the first templates in card.

Suzuki Rmh470

O Right: This means that everything can be easily altered until it looks right.

the 'Simons' forks were acquired from America, costing €30 and €400 respectively but they also have undergone many hours of treatment. The front fender was remade with a blade cutter and cut to remove the top layer of plastic that had been baked by the sun, 1 then sanded it with 600, 1000 1500, and 2000 sandpaper and polished it to finish."

The rear hub had to be repaired and repainted before re-spoking into an Excel rim and also needing work were the shocks - originally from a 1980 RM125 - which had to be completely rebuilt with new seals and springs before being repainted.

"I wanted the airbox as large as possible so that the engine breathes properly so I took the largest dimension possible, taking into account other elements like the suspension and exhaust pipe," explained I-F.

"Initially, I cut the aluminium sheets of 1mm in the form of the paper templates and I fixed them together with rivets, but I abandoned the idea as it was too complicated, not strong enough and not easy to modify.

"So I decided to go with 2mm aluminium (AG3) as it is easy to weld with TIG and can be modified." After many alterations the finished airbox is held firmly in place by five screws through lugs on the frame.

The front number plate is made in a white, translucent plastic bought in US but the fasteners are home-made with 2mm alloy - grade 5754 -which he formed at home. Whereas the side plates and silencer, while in the same grade of aluminium, were 1mm thick.

Not exactly dear

The total build costs amount to €1942 but, rounded off and taking into account a few small items that may have been forgotten, a guesstimate brings the total figure to €2000 -which equals £1808.65 according to the

O Above: As with any special, ifs often easier to make the first templates in card.

O Right: This means that everything can be easily altered until it looks right.

Frame, swinging arm, rear hub acquired for €120 400DR 1980 €150

400GN 1980 €100 plus €100 transport

Fox and Monoshock rear mudguard 125RM1980 €100

News springs for Fox shocks €60

Simons Forks €400

Foam seat, seat cover, brake shoes, handlebars €200

Wheels - complete restoration including tyres €500

Gasket kit engine €30

Chain and sprockets €120

Base painting and sanding by owner, so €0

Final top coat of paint, one bottle of whisky!

Mudguard Preston C30

Tank €20 (Without the loel Robert signature. I met him at the MX of Nation at Ernee France in 2005,1 come with the tank and he signs it to me with a smile) Air filter €12

Skid chain of the swingarm attached chassis €70 Elbow and tubes for exhaust pipes €50 Anodizing aluminium parts made by the company of a friend - more whisky The handmade parts for the bike didn't cost anything as lean-Francois did everything with reclaimed materials of good quality. Time consuming, yes. but possible.

Simons Forks

O Simons forks mate wen to the DR hub. O The spindle needed spacers turning up to mate the hub to the swinging arm.

Dirt Bike Swing Arm And Chassis

O Much repair work went into the swinging arm.

piece was manufactured and checked and confirmed for fitting for position etc. A final definitive part was then manufactured for aesthetic reasons."

O Its a tight squeeze tor the electrics under the petrol tank.

currency converter site on 8 March 2010. That's not bad for a machine of such quality. Of course this does not take into consideration the endless hours of toil and effort gone into the manufacture ofparts.

That in itself is immeasurable as the Frenchman goes on to explain: "I estimated that each manufactured piece of the bike has been remade about three times, in particular the mounting lugs welded to the frame, the engine plates, inserts in the frame, side plates, spacers, the exhaust and the airbox."

He continues, "After the initial plan or template was made, the piece was manufactured and then welded or attached to the bike to see if it worked, or if further modifications were necessary. If modifications were necessary then the second

O Simons forks mate wen to the DR hub. O The spindle needed spacers turning up to mate the hub to the swinging arm.

O Much repair work went into the swinging arm.

O Its a tight squeeze tor the electrics under the petrol tank.

piece was manufactured and checked and confirmed for fitting for position etc. A final definitive part was then manufactured for aesthetic reasons."

Technical hitch

A problem encountered with the action of the kick-starter hitting the right footrest caused a few headaches until a brilliantly simple solution involving a hook was devised. "I spent a lot of time finding a solution that worked and making the necessary parts. The current system works well with just a simple kick," explains Jean-Francois.

Topping off the smart machine is a TM125 fuel tank he obtained for the princely sum of €20 -once restored it was signed by six times world champion Joel Robert. "It's small and looks like the YZ125C alloy tank used by Sten Lundin when he built the HL500 for Bengt Aberg," claimed the affable Frenchman.

The eye-catching machine drew a great deal of attention over the Farleigh weekend, including interest from Suzuki specialist Jan Geboers. ■

Jan Geboers

O Unfortunately the tank doesn't look like this now - thanks to the lirst corner melee.

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