This handmade 2WD motorcycle is one of my custom all-wheel drive projects. I built this bike as a hobby project for off-road riding and experimentation. The motorcycle is powered by a Yamaha Serrow 225cc engine with electric start.
I built the chassis using 1-inch and 3/4-inch box steel tubing. The ground clearance from the ground to the engine is about 35 cm, and the wheelbase is around 160 cm measured from the center of the rear hub to the center of the front hub.
Both the front and rear wheels are powered using chain drive systems. The motorcycle was designed mainly for off-road riding and difficult terrain.
Rear Swing Arm of the Handmade 2WD Motorcycle
The rear section uses a handmade single-sided swing arm. I designed the swing arm so the rear hub position can be adjusted to set the chain tension properly. The rear hub itself is also fully handmade.
The rear wheel uses a disc brake system. The brake disc and caliper were removed from a car and modified to fit this bike. The rear sprocket is a 520 size 48T sprocket, while the engine output sprocket is 13T.
You can watch the rear swing arm and rear hub fabrication videos on my YouTube channel.
Handmade 2WD Motorcycle Front Drive System
The front wheel is also powered directly from the engine using a chain drive setup.
First, the engine drives a 32T sprocket using a 428 size chain. That sprocket then drives another 32T sprocket. I used a front wheel lock system taken from a 4WD van for this setup. This allows the front wheel drive system to be turned ON or OFF whenever needed.
This is one of the special features of the motorcycle. During normal road riding, the 2WD system can be turned OFF. When riding on difficult off-road terrain, mud, or loose surfaces, the 2WD system can be switched ON for extra traction.
The 2WD ON/OFF control is connected through an axle running along the right side of the bike. The front disc brake system is also built onto the same axle assembly. A 13T 520 sprocket is mounted there as well.
From the 13T sprocket, a chain drives the 48T front sprocket. After that, a CV joint is used to transfer power to the front hub. This allows the front wheel to continue receiving power even while turning the handlebars.
The front wheel also uses a handmade single-sided swing arm similar to the rear setup.
You can also watch the front hub and front swing arm fabrication videos on my YouTube channel.
Handmade 2WD Motorcycle Steering and Suspension
The steering system works using a tie rod connected from an arm on the hub assembly to the handlebars through a linkage bar. The working system can be understood more clearly by watching the motorcycle while riding.
GIF showing how the front wheel steering system works.
Both the front and rear suspension use mono shock absorbers.
Handmade 2WD Motorcycle Wheels and Tires
Both the front and rear wheels use car rims. Sometimes I use 12-inch rims with 6.00-12 tractor tires. These tires give very good traction in mud and difficult off-road conditions, but they create a rough riding feeling on normal surfaces.
For regular off-road riding, I usually use 14-inch rims with Yamaha TW rear tires sized 180/80-14. These tires provide a much smoother riding experience and better comfort.
Custom Handmade 2WD Motorcycle Parts
Many parts on this motorcycle were handmade, including:
- Fuel tank
- Mudguards
- Seat
- Handlebars
- Chassis
- Front hub
- Rear hub
- Front and rear swing arms
The complete build videos and fabrication process videos can be seen on my YouTube channel. Make and Ride
This motorcycle was built very differently compared to ordinary motorcycles used for daily riding. Riding this machine gives a completely different experience and a unique type of off-road fun.