Most motorcycles are designed for normal roads. But I wanted to build a motorcycle that could ride through mud, rough terrain, steep hills, and difficult off-road trails.
This handmade 2WD motorcycle was inspired by the legendary Rokon bike and built for extreme off-road riding.
Chassis Design and Bajaj Pulsar 150cc Engine
The chassis of this bike was fabricated using 1-inch and 1.5-inch box steel tubing with a thickness of 1.6mm.For the engine, I used a 150cc self-start air-cooled Bajaj Pulsar engine.
The bike uses a custom handmade leading-link front suspension system instead of traditional motorcycle forks.
The front hub was also fully handmade. A front brake unit was not added directly to the front hub.
Both the front and rear wheels use 12-inch rims with 5.00-12 tractor tires.
The same tire size is used on both ends of the bike for better off-road balance and traction.
Both the front and rear wheels are driven by chain systems, making this a true 2WD motorcycle.
Handmade 2WD Motorcycle Front Drive System
The front wheel drive system works completely through chains and sprockets.
Power starts from a 14T engine sprocket and transfers through a chain to another 14T sprocket mounted on a custom CV axle assembly.
A custom CV joint system was used to transfer power to the front suspension while still allowing steering movement and suspension travel.
One side of the CV axle is connected to the chassis, while the other side is connected to the front fork assembly.
On the front fork side, another 14T sprocket is mounted to the CV shaft.
A custom front brake unit was also integrated into this section.
From there, power transfers through another chain to a 428-32T sprocket.
On the opposite side of the same axle, another 14T sprocket sends power through a final chain to the 428-45T sprocket mounted on the handmade front hub.
This video shows the most important part of the entire 2WD system — the custom front wheel drive unit. The fabrication process includes the handmade front hub, leading-link suspension, custom front brake assembly, and the CV axle system that makes front wheel drive possible while steering.
Custom Rear Swing Arm and Rear Hub Design
The rear section uses a custom single-sided swing arm design.
The rear hub was welded directly to the swing arm assembly.
Like the front wheel, the rear wheel also uses a 12-inch rim with a 5.00-12 tractor tire.
On the rear axle, the brake disc is mounted first, followed by the chain sprocket.
The rear sprocket size is 428-45T.
The front and rear wheel speeds are matched using the same sprocket ratios.
Power flows through the 45T to 14T sprocket setup, then through the shaft and 32T sprocket before reaching the engine’s 14T sprocket.
A mono-shock suspension system was used for the rear suspension setup.
This video shows how the custom rear swing arm and handmade rear hub were built for the motorcycle. The fabrication process includes the single-sided swing arm design, rear brake setup, sprocket mounting, and rear chain drive assembly.
Handmade 2WD Motorcycle Chassis and Chain Drive System
The following build video shows the complete fabrication process of this handmade 2WD motorcycle. It includes the chassis construction, custom chain drive system, and the full drivetrain setup used to transfer power from the engine to both the front and rear wheels. The video also demonstrates how the motorcycle performs after the build was completed.
Handmade 2WD Motorcycle Performance
Although this motorcycle uses only a 150cc engine, the custom drivetrain setup produces extremely high torque.
The bike is powered by a Bajaj Pulsar 150cc air-cooled engine, which normally produces around 13.25 Nm of torque. However, because power passes through multiple chain and sprocket reductions, the final wheel torque becomes much higher than a standard motorcycle.
The complete drivetrain uses a total gear reduction ratio of approximately 7.35:1.
This means the engine output shaft must rotate about 7.35 times to rotate the wheel once.
Because of this setup, the bike produces excellent pulling power, climbing ability, and off-road performance.
The estimated wheel torque in each gear is approximately:
1st Gear – 280 Nm
2nd Gear – 183 Nm
3rd Gear – 134 Nm
4th Gear – 105 Nm
These torque figures are much higher than a normal 150cc motorcycle, making the bike very capable in mud, rough terrain, rocky surfaces, and steep hill climbs.
The motorcycle was designed mainly for off-road riding rather than high speed.
Its top speed is around 35 km/h, which is more than enough for difficult off-road trails.
One limitation of the current setup is that the 2WD system cannot be switched on or off.
Also, a one-way freewheel system was not added to the front wheel. Because of this, steering becomes slightly harder at higher speeds, especially while cornering.
Before completing the full bodywork and final finishing of the motorcycle, the bike was assembled into a rideable condition for testing. The following video shows an early test ride of the handmade 2WD motorcycle, demonstrating the performance of the custom drivetrain, front wheel drive system, suspension, and overall off-road capability.
Handmade Body Parts and Final Mechanical Assembly
Many additional parts of this motorcycle were also handmade, including the fuel tank, seat, mudguards, chain case, rear carrier, and footrests.
The following video shows the fabrication and installation process of these components, along with the final mechanical assembly of the motorcycle before painting and cosmetic finishing. At this stage, the main drivetrain systems, suspension, body parts, and functional components of the bike were completed and assembled into a fully working condition.
Final Paint, Assembly, and Riding Demonstration
After completing the fabrication and mechanical assembly work, the motorcycle was fully painted and reassembled into its final form.
The following video shows the completed handmade 2WD motorcycle after painting, including the final assembly process and riding demonstration. The finished bike features a rugged military-style appearance, custom front wheel drive system, handmade chassis, and high-torque drivetrain designed for off-road riding.
You can also explore my other handmade motorcycle and custom fabrication projects on BuilderX Garage.