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    Re: Yamabuggy 400 swap to 900
    #21
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    I don't know why, but left side didn't want to weld. Welded in one time on the right side.





    Reverse box was a pain to install. Must be align perfectly with the gearbox output. My oncle brought me help.




    Now it's time to install rear transmission. On left my 52 teeth sprocket, on right original from donor bike




    And here is the drama. When the sprocket is fix on the live axle , I realize that they are not parallel




    More than 3 millimeters apart ! And yet I am not at the end of the sprocket. My turner and milling machine operator passed it to the marble, the live axle is welded askew. After contacting the manufacturer with photos files, they will send me a new one with checkup control.
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    Re: Yamabuggy 400 swap to 900
    #22
    Duck in a Tux jimmyg's Avatar
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    Odds are 3mm would have be ok but better not to take the chance and fix it.
    All dressed up and waiting for the beer to arrive.
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    Re: Yamabuggy 400 swap to 900
    #23
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    I received the new axle, it was worse than the first one (newest on left)




    So it get back to the company and they sent me the axle as a kit, to assemble it by the pro welder. Result is good :




    Creation of the stainless steel exhaust line, in 51mm :





    We position the line in the frame, it is a question of determining the shape by following the grid, avoiding the gearbox control rod (which I will document later), the reverse gearbox and finally bring out the line in front of the original location :




    Just need to add OČ sensor and find an exhaust muffler.

    One of my bigger fear on this project is sprockets alignment. I imagine this tool. Next step is making axle support on the chassis

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    Re: Yamabuggy 400 swap to 900
    #24
    Duck in a Tux jimmyg's Avatar
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    Looking really good!
    All dressed up and waiting for the beer to arrive.
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    Re: Yamabuggy 400 swap to 900
    #25
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    OČ sensor recovery




    Then welded on the previous line




    This is how I created the gearbox linkage. Originally there is already a lever that operates the gearbox control and the clutch on the buggy because it was equipped with a Yamaha bigbear engine. The part that goes from the lever to the angle transmission I have kept. After the angle transmission, it is the control specific to the motor. You need a personalized one that corresponds to the 900 TDM. On the left before transformation, on the right after.




    After more than one hour of work, I install the rod, nothing touches when I operate it by hand. I do it from the lever between the two seats and there it is the cold shower: gears up/down but the rod is deformed above the alternator housing . I can't find a thicker rod, nor in the nearest hardware store. So I buy a threaded rod in M16 and I file the thread on 80cm: On the right the faulty rod, on the left the filed M16.

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    Re: Yamabuggy 400 swap to 900
    #26
    Duck in a Tux jimmyg's Avatar
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    Heaps of work been going on. Get close to finished. Well done.
    All dressed up and waiting for the beer to arrive.
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    Re: Yamabuggy 400 swap to 900
    #27
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    Grinder for cut and make place for rear axle.




    Like the gearbox linkage, i started to work with a to small size angle iron




    Two supports like this, one for front one for rear




    We weld all the angles iron to the frame, the axle is just points welded because I have a doubt about its alignment with the engine. The tool you saw previously to perform this task does not give me 100% confidence in use.

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    Re: Yamabuggy 400 swap to 900
    #28
    Duck in a Tux jimmyg's Avatar
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    I was wondering how you were going. Not heard from you for a bit.

    Glad to see your still going well.
    All dressed up and waiting for the beer to arrive.
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    Re: Yamabuggy 400 swap to 900
    #29
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    Quote Originally Posted by jimmyg View Post
    I was wondering how you were going. Not heard from you for a bit.

    Glad to see your still going well.

    Thanks for your concern .

    Lot of money spent, it's not to quit now . In reality, the buggy is much more advanced than what you see now, I just need to find time between the children, work and the buggy building for update my topic .
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    Re: Yamabuggy 400 swap to 900
    #30
    Duck in a Tux jimmyg's Avatar
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    Quote Originally Posted by Julien51 View Post
    I just need to find time between the children, work and the buggy building for update my topic .
    This 100% for me to.
    All dressed up and waiting for the beer to arrive.
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