The Diesel Project

[OldmanofMn]

I once started a project of my own i bought a wrecked honda Shadow 500 and was going to mount it in an old Honda Pilot Atv would of been the Pre (RZR) Had it all figured out to run on the shaft drive thru a jack shaft setup. But you know how (The MRS) can get lol.
The plans all went south :(

[cheesy]

Got the truck unloaded this afternoon. Because it was just me, myself, and I, I ended up yanking what’s left of the engine so I could get the frame down. Trans won’t go into gear, so I will open it up in the near future to see what’s what. If nothing else, it’s in dire need of a shifter shaft seal.

[cheesy]

Ha, shifting problem solved. Something simple but hard to find. The shift drum wouldn’t turn. It wouldn’t turn because the detent pin was seized. I moved it enough to free up the drum and it went through the gears just fine. I just need to get that pin freed up.

[cheesy]

Not too sure the zuki trans will fly. Counter rotating, wet clutch, lots of aluminum modding. I will stare at it some more and see if I can come up some kind of work around.

[cheesy]

After some brainstorming with some diesel bike guys across the pond and pondering all the options they presented, looks like I will be sticking with the Suzuki 6 speed transmission. I can replace the crankshaft with a straight shaft to use as a jack shaft. That way I can still use the wet clutch and not need to hack or mod the case.

It’s a start.

[cheesy]

I don’t what is in the Suzuki-Bond thread locker but it is some kickass stuff.

Once I get the flywheel/rotor off, and it’s being stubborn, I can split the case. Once that is done, I can pull the crank as an assembly, knock the primary gear off of it, and figure out what I need to make a jack shaft. None of that will happen, though, until the flywheel comes off.

[Bruces]

You used to have a plasma cutter in your cluttered old shop ,If it made it to the new shop it’s time to fire it up .

[cheesy]

Originally Posted by Bruces

You used to have a plasma cutter in your cluttered old shop ,If it made it to the new shop it’s time to fire it up .

That’s if nothing else works.

[cheesy]

Whelp, time for Plan B. Or is it C? Anyway, after a re-review of my options, no way Plan A is going to work. Primary gear is part of the crankshaft casting and not removable. Using the entire lower half of the Suzuki engine along with the diesel would necessitate lengthening the frame. Don’t want to do that, either.

So, I am back to hacking the transmission off the front half of the Suzuki block. After having split the case, it is starting to look like the better option, anyway. If I eliminate the no longer needed oil pump, I knock around 10” off the length of the block, which gives me plenty of room for the diesel. Once all my measurements are done and double checked, I’ll put the gutted halves of the block back together and drop it off at my buddies’ machine shop for a trip through the horizontal band saw.

[lilgman]

I can't wait to see how this all works out!

[Darkrider]

So if i am reading all this right. The current plan is to hack what is left of the Suzuki engine and more or less convert the transmission half into a stand alone gear box like a harley?

[cheesy]

Originally Posted by Darkrider

So if i am reading all this right. The current plan is to hack what is left of the Suzuki engine and more or less convert the transmission half into a stand alone gear box like a harley?

You read it right.

[Darkrider]

Originally Posted by cheesy

You read it right.

Def looking forward to seeing how this turns out.

[wheelbender6]

I have seen some electric motorcycle conversions where the original ICE gearbox was retained and used with the new electric motor. There are some of those threads on endless-sphere.com

[franque]

The classic unit to pre-unit conversion... Are you going to teach yourself casting and make a cool primary cover? That would be so cool! Or maybe you should adapt some train parts, based on your vocation