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...........:Punk:

[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.

http://i48.photobucket.com/albums/f202/Jedi-NZ/Yamaha%20XV750/PIC00221Small.jpg
http://i48.photobucket.com/albums/f202/Jedi-NZ/Yamaha%20XV750/PIC00223Small.jpg
http://i48.photobucket.com/albums/f202/Jedi-NZ/Yamaha%20XV750/PIC00226Small.jpg
http://i48.photobucket.com/albums/f202/Jedi-NZ/Yamaha%20XV750/PIC00228Small.jpg
http://i48.photobucket.com/albums/f202/Jedi-NZ/Yamaha%20XV750/PIC00230Small.jpg
http://i48.photobucket.com/albums/f202/Jedi-NZ/Yamaha%20XV750/PIC00234Small.jpg
http://i48.photobucket.com/albums/f202/Jedi-NZ/Yamaha%20XV750/PIC00239Small.jpg
http://i48.photobucket.com/albums/f202/Jedi-NZ/Yamaha%20XV750/PIC00241Small.jpg

[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/attachment.php?attachmentid=50754&d=1168664881
http://www.kiwibiker.co.nz/forums/attachment.php?attachmentid=50755&d=1168664881
http://www.kiwibiker.co.nz/forums/attachment.php?attachmentid=50756&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/showthread.php?t=42114&highlight=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.

[jedi]

The wheel should run a 200 tyre and I will be making a new swing arm from scratch that will be about 3 or 4 inches longer than stock.
Should start it this weekend.

[jedi]

Made a crude looking jig to fab the swing arm taken from stock setup and frame datum points. Then I made it and is about 4" longer than stock, I still have to make the tunnel tube to motor and the axle but it's coming along. I have also made a new neck and raked it out slightly.

[degrom]

Looks great!!!
What would you charge for making this kind of thing for other people?

[surfer]

Really nice work Jedi

[jedi]

Well as you can see I have made the drive shaft to suit. I didn't have my camera at work today so I don't have any "making it pics" however it's done and I can shorten it to whatever length I require as I made the rear spline longer. The material is k600 otherwise known as 2767 otherwise known as EN30B and will be thru hardened to about 45 RC. We use this material alot for half shafts and axles for drag cars etc and is ideal for such applications.

[degrom]

Well as you can see I have made the drive shaft to suit. I didn't have my camera at work today so I don't have any "making it pics" however it's done and I can shorten it to whatever length I require as I made the rear spline longer. The material is k600 otherwise known as 2767 otherwise known as EN30B and will be thru hardened to about 45 RC. We use this material alot for half shafts and axles for drag cars etc and is ideal for such applications.

Hi,

Whats happening with the XV?

(Is it done and do you have some pictures?)

Cheers for now.

[Macktheknife]

Love your work Jedi, wish I had the skills you do, not to mention the machinery. Beautiful job, can't wait to see it finished. Maybe when you are done all of us with choppers can go for a cruise somewhere. I know at least 1 other who would be keen.

[jedi]

Hi, yes I have done a little more, the swing arm has been fully welded with gussets added and I have mounted the rear brake caliper. I roughly sprayed the swing arm etc just to stop it rusting until I get it powder coated. The guard is just for mockup and the bars to push it around the shop. Next up is to do some tin work to meet the seat area. Still lots to do but it's getting there. It's not going to be a major project as it is just a daily hack to ride to work and back.
I have a XV100 motor that's going to be a scratch build starting soonish with new frame etc.

[degrom]

Looks good!!! ;)

[jedi]

Had some spare time and made some brass grips which will fit my internal throttle.

[degrom]

Had some spare time and made some brass grips which will fit my internal throttle.

How long did it take to make those? :)

Looks like am commercial product...

[jedi]

How long did it take to make those? :)

Looks like am commercial product...

About 2 hours. The grooves I cut with a timing belt cutter ( gear cut).

[degrom]

About 2 hours. The grooves I cut with a timing belt cutter ( gear cut).

Is that a lathe with the timing belt cutter?

I thought gears was made on a mill...

Very interesting stuff mate!!! Looks Great!!!

[jedi]

No, that's a Barber Coleman gear hobbing machine. We bought a new cnc lathe
a couple of weeks ago and that's how I machined them prior to gear cutting.

[jedi]

Here's a small update, I have stretched the tank with some tin and got the wheels and swing-arm powder-coated. I will also dismantle the diff housing and powder-coat it also. Virago fans will recognise the fugly front wheel has been enhanced by making some inserts that were laser cut after I made some templates and then attached them to the wheel casting webs. I think it now makes the wheel ok.
I have also machined some risers, grips and mocked up the bars.
Everything is just mocked up at present. Some body extention work to do around the seating area next on the list.

[degrom]

I see progress!!! Looks good.. :)

What colour are you going to make it?

[jedi]

I see progress!!! Looks good.. :)

What colour are you going to make it?

There is only one colour....Black:yes:

[Macktheknife]

There is only one colour....Black:yes:

I am curious though mate, can you do bars for anyone else?
I am keen to get some made for my chopper because I can't find what I want. Is this something you would consider or know someone else?

[jedi]

I am curious though mate, can you do bars for anyone else?
I am keen to get some made for my chopper because I can't find what I want. Is this something you would consider or know someone else?

Yes, should be able to, what do you have in mind?

[Conquiztador]

Just found this. Interested to know how far you have got with her?