XV750 to Suzuki shafty wide-wheel conversion

[jedi]

I'm not sure if you guys are really into this sort of stuff or not , but I'll post it anyway.. I'm chopping my next project and converting the rear wheel to a wider Suzuki 200 so I made an adaptor for it...

[98tls]

If its modding then im into it...........awsome work.......please post up pics when fitted eh...........

[jedi]

To make the drive flange fit the wheel I first had to machine down some of the bearing spigot face inside the wheel to allow the flange to fit down enough. Next op was to mill the drive tabs on the drive flange to mate with the cush drive and then bore out the flange to accept the drive spline that fits to the drive plate flange.
The drive spline was bored hollow and gear cut on expanding mandrel as shown in one of the pictures. A picture also shows the drive spline after I cut it.
I pressed the drive spline into a recess machined in the drive plate and tig welded on both sides of the plate. The drive plate fits into the cush drive and the spline mates to the shaft drive unit.
The original drive shaft to motor gets pulled out and next task is to make the universal joint to drive unit spline adaptor so it fits it. The concept is to run unviversal joint to universal joint so that no offseting is required from the motor output, so in other words the drive shaft will be running at an angle. More pics will follow when I finish the universal joint splines and I'll also make a new shaft between the U/j's. I expect to run the rear end about 3-4" longer
than stock.

[jedi]

Next part of this was to make a universal joint to fit the drive unit. I got one from a bike wrecker down the road which was out of another shaft drive from something or other which I'm not sure, anyway I had to dismantle it to machine it. One pic shows the U/J that has been machined down to accept a splined sleeve made to suit it, also in the picture is a rear cap for the U/J which has a blind hole in it for a push spring that runs inside the drive unit. This is to allow the yoke spline to float slightly back and forth over its length to stop any binding thru the arc travel of the swing arm. That kind of setup is really just like a common tail shaft setup from a car where the tail shaft can slide up and down a little on the slip yoke to stop any binding from any short movements. One other pic shows the reassembled and mounted U/J inside the the drive unit and is ready to go apart from the axle, rear U/J to motor U/J and a shroud which I'll make to keep the crap away from the drive unit /wheel, plus a sleeve will need to be made to run between the drive unit and first wheel bearing so it doesn't crush the bearings when the axle is tightened.

[98tls]

Very nice..........have you got a pic or two of the bike in your avatar......what year motor and whats been done............

[jedi]

Very nice..........have you got a pic or two of the bike in your avatar......what year motor and whats been done............

The bike in my avatar is my Honda project which is posted here somewhere.. these were the pics to date..
http://www.kiwibiker.co.nz/forums/at...4&d=1168664881
http://www.kiwibiker.co.nz/forums/at...5&d=1168664881
http://www.kiwibiker.co.nz/forums/at...6&d=1168664881

[98tls]

Will do a search..........much respect to you for what your doing.......wish i had the skills...........all my modding comes by way of buy and bolt on.

[jedi]

the link was here... http://www.kiwibiker.co.nz/forums/sh...ight=honda+750

[98tls]

Love it............some pretty serious gear behind it as well eh.

[Clivoris]

Wicked skills mate.

[Meanie]

Thats dam clever, Great to see talent not wasted
Keep them updates and pics coming

[Waylander]

Odd that Wired1 and Pat have not posted in this thread yet. Both of them are currently working on XV750 projects themselfs.

[degrom]

Odd that Wired1 and Pat have not posted in this thread yet. Both of them are currently working on XV750 projects themselfs.

Wired1 is on his way... (just mailed him!!!) This is really amazing stuff!!!

Luckily I have the XV standing in my garage... All I now need to get is the skill's to do this conversion!!!! LOL

[bistard]

Bloody nice work mate!!

[degrom]

Next part of this was to make a universal joint to fit the drive unit. I got one from a bike wrecker down the road which was out of another shaft drive from something or other which I'm not sure, anyway I had to dismantle it to machine it. One pic shows the U/J that has been machined down to accept a splined sleeve made to suit it, also in the picture is a rear cap for the U/J which has a blind hole in it for a push spring that runs inside the drive unit. This is to allow the yoke spline to float slightly back and forth over its length to stop any binding thru the arc travel of the swing arm. That kind of setup is really just like a common tail shaft setup from a car where the tail shaft can slide up and down a little on the slip yoke to stop any binding from any short movements. One other pic shows the reassembled and mounted U/J inside the the drive unit and is ready to go apart from the axle, rear U/J to motor U/J and a shroud which I'll make to keep the crap away from the drive unit /wheel, plus a sleeve will need to be made to run between the drive unit and first wheel bearing so it doesn't crush the bearings when the axle is tightened.

Had a look at my XV and wondered about your project...

Are you going to modify the swing arm as well?

My bike has a 120 back tire and it fit's really tightly against the swing-arm giving you about 10mm on the left and say 30mm on the right.

I am sure you have thought about this,just wondering what you are going to do...

Good luck with the project.