K1100 16V Turbo build...now transmission build.
Turbo Mini Forums

MW3 - I don't think I'd like to try and replicate this one! lol

I might be able to get the shafts, adapters, and gears made up for people though, to convert there own?!

Im not sure about the gear ratios. There are a fair few variations around on the different bikes, so quite possibly one of the bigger engined tourer bikes might have a higher over drive. As far as I know they can be swapped about.

Joe - I haven't looked at them boxes, although, they may well of been the ones used in Aus for these conversions. I'll see if I can find some pics, but im pretty sure I can get this setup to work.

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1/4mile in 13.2sec @ 111 terminal on 15psi

Joe - ive had a look at the boxes you mean. They would make it easier to keep a linkage type shifter. Im going to make a new end plate for the box, with the solenoid mounted for reverse and an external lever lever. It will be operated using a cable, so at least then I can do away with the actuator push button type shifter.

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1/4mile in 13.2sec @ 111 terminal on 15psi

Righty, centre web is pretty much finished ready for some uber accurate measuring and pilot drilling ready for the line boring.

The main problem is what bearing to use for the input shaft?

Ideally I'd like to use the same bearing as on the 1st/3rd motion shafts to keep things simple, but because of there OD im not going to be able to get the two shafts close enough together.

Does anyone have any suggestions? It needs to have a bore to suit a 1" shaft and be no larger than 50mm OD?

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1/4mile in 13.2sec @ 111 terminal on 15psi

width matt?

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM

Well standard mini bearing is 26.90mm (ish), so maybe around the 20-22mm?

The centre web plate is 25mm thick but I need a shoulder for it to sit up against.

Ive just measured a standard 1st motion drop gear (helical) and it is 56.09 to the inner most part of the tooth core. So it may be possible to use a couple of SC drops as the 2 extra drop gears I need, as they may end up being the right distance between centres when meshed!?

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1/4mile in 13.2sec @ 111 terminal on 15psi

Some pics of the centre web so far...

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1/4mile in 13.2sec @ 111 terminal on 15psi

hmmm ,had an idea , couldn't you mount the box onto the saddle of a big enough lathe ,then use a boring bar in the chuck ,and on a centre in the tail stock ,through a rough hole in the centre plate to line up with the end plate hole,then just move the saddle down the bed on power feed ?

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM

What your plan for holding the plate straight whilst welding it? As if I was building it I'd end up welding it in on the piss.

Robert - that is a possibilty, adjusting the height mighy be a bit of a nightmare though? Ithink im going to pilot drill the holes near size then make up mock bearings out of ally to check centres and clearances.

Rob - it only really fits in one place' but im using one of the bearing retainer holes and some parallels clamped to the exisring part of the centre web.

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1/4mile in 13.2sec @ 111 terminal on 15psi

Robert - that is a possibilty, adjusting the height mighy be a bit of a nightmare though? Ithink im going to pilot drill the holes near size then make up mock bearings out of ally to check centres and clearances.

Rob - it only really fits in one place' but im using one of the bearing retainer holes and some parallels clamped to the exisring part of the centre web.

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1/4mile in 13.2sec @ 111 terminal on 15psi

Just a bit of trimming to do now. Im not sure wether I should grind the fins down either side of the plate, so its got something a bit more substantial to be welded to?

It turns out I can't use standard input gears toegther so looks like its going to be some custom ones. Ive been thinking about running the engine backwards to avoid the extra gear, the only major problem I can think of is the direction of the oil pump, which I can't see an easy solution to?



This ones for you Colin.

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1/4mile in 13.2sec @ 111 terminal on 15psi

Edited by Sprocket on 5th Dec, 2011.

I was thinking that, but I was unsure on how much resistance there is when the pump is at full pressure, not sure if its asking for trouble. I suppose if the belt wraps most of the way around the pulley it could work.

Im guessing the starter could be rewired to drive in reverse.

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1/4mile in 13.2sec @ 111 terminal on 15psi

All is looking good, can't get my head around the gearbox build yet, but the bulkhead and steering column mount look great.

Cheers george, it will all become clear.

Ive finished the end palte now, just got to work out what depth to sit it at.



And my new shifter...work in progress..

Edited by matty on 6th Dec, 2011.

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1/4mile in 13.2sec @ 111 terminal on 15psi

matt id make a couple of tight bungs to fit in the bearing holes for welding so they dont go out of round ?

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM

I was hoping the original bearings and mainshaft fixed in place would be good enough, what do you reckon?

Robert - When you measured the centres of the shafts, was it from centre to centre of each shaft? Something doesn't add up when I use the 59.60mm dimension, it looks to close?

I still haven't got my gearset back to check.

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1/4mile in 13.2sec @ 111 terminal on 15psi

On 6th Dec, 2011 matty said:
I was hoping the original bearings and mainshaft fixed in place would be good enough, what do you reckon?

Robert - When you measured the centres of the shafts, was it from centre to centre of each shaft? Something doesn't add up when I use the 59.60mm dimension, it looks to close?

I still haven't got my gearset back to check.

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM

I assume it's not possible to drill it slightly undersized and ream it after welding to insure that it's perfectly round? Or is it physically impossible to do any machining after welding?

Robert - I see your point (so to speak), I'll machine up some steel bungs for it. I think i'll put some threaded studding with a lock nut each side of both of the bungs too, hopefully that'll keep the distance bewtween them the same.

Rob - All the new holes that need drilling will be roughed out before welding, then line bored afterwards. Roberts talking about the original 1st/3rd motion shaft bearing locations distorting/collapsing during welding.

Edited by matty on 7th Dec, 2011.

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1/4mile in 13.2sec @ 111 terminal on 15psi

or just use an external one and ditch the mini cam altogether.

That would be simple enough - an external electric pump with pre filter sucking the oil out of the sump plug hole and pumping it straight into thru galleries near the relief hole

I wouldn't like to trust my engine lubrication to an electric pump. Do they even do one that could do the job?

If something is worth doing, it's worth doing half of.