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Old 05-29-2010, 09:46 PM   #1
fritster
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Default GSXR 600 Build frame up

pics so far of my build. I hope it works well?

Scotty B and a few others have given valuable help on this project. Thanks to all those who have helped. I cannot wait to test the suspension in a couple of weeks.

old marathon junky suspension.jpg

ezgo front.JPG

shock mounts and wattslink.JPG

swingarm and control arm mounts.JPG

DSC00947.jpg
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Old 05-31-2010, 05:35 PM   #2
fritster
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Default Re: GSXR 600 Build frame up

For me, I must now decide on these 2 choices to turn the rear diff:

1. chain from the MC engine to a small sprocket on the diff shaft with a gear reduction to 6 0r 8:1... and clutch shift thru the gears like the MC. I need adivice on how to mount the sprocket on the rear diff shaft and do I need to fabb up a sleeve to slide over the end of the splined diff shaft with a bearing that mounts to the swingarm some way to keep the diff shaft and sprocket nice and secure with the sleeve acting like a counter balancer to keep the torque form the chain in under control?

2. chain from the MC engine to a jackshaft setup to turn a primary cvt clutch that drives the stock secondary clutch on the diff via belt.... and maybe a diff gear reduction also? What I like about this setup is that you just choose a comfortable gear on the MC (5th or 6th) and its more like an automatic... just press the gas and hold on.. ease of use?

MACBOOST used the CVT setup but blew the CVT primary more than likely because of turning such high rpms to get some speed going. I am waiting to hear how his new CVT from Tom (rated to handle 100 hp) will work and I wish he would do the gear reduction so i could make up my mind here...LOL

Of course I am also waiting to see on this thread and maybe anothers how the small sprocket on the diff works out, especially with a gear reduction???

IF YOU ARE USING A SMALL SPROCKET MOUNTED ON THE REAR DIFF, DRIVEN BY A CHAIN FROM THE MC ENGINE AND U HAVE A GEAR REDUCTION... PLEASE EMAIL PM, ME TO ADVISE PROS/CONS OR MAYBE CALL ME? 337 652 1600

ughhh......
Trying to decide is the hardest part sometimes. I started this project putting the cart before the horse and because of that have had to return a lot of things.... so now I am trying to decide with some help from the expereinced guys.. the pros on here, like Rifter, Scottyb, Macboost and Hillbilly and the many more that have given me advice and helped me with everything from suspension questions, shocks, swingarm design and now the drive train issues.

Any advice is always aprreciated.
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Old 06-02-2010, 03:38 AM   #3
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Default Re: GSXR 600 Build frame up

What I'd personally do is...


Get a sleeve machined ((circled in red) Get it machined to the length of the splines and use the stock bolt with washer to hold in place)

Get one of these:
http://www.princessauto.com/farm/dri...es-weld-on-hub
Probly would also want to weld this to the sleeve after everything is dialed in cause i can't see the 2 set screws holding on with major toque
and one of these:
http://www.princessauto.com/farm/dri...ld-on-sprocket

The hubs come in a bunch of different bores, and there is a wide variety to the sprockets ranging from 10 teeth up to 72. That way you can run a 520 chain (since your motor probly has a 520 sprocket, or a 530)

That way you can find out the stock sprocket gearing and tire size from the bike. Then do a little math figure out what ratio your gonna run in your transaxle and what tire size on the cart.

Then you can other:

a. find out what front and rear sprocket you'd need to get you the same over all gearing with your trans axle and tire combo as the bike and adjust as you seem fit to get a nice top speed but still have low end power

b. pick a top speed you'd like to hit and crunch some numbers and find out a gear ratio

c. ignore everything I said and find a easier less math involved process.

Just thought I'd throw in my 2 cents as these are some thoughts I've had. I'm just a 19 year old back yard mechanic. I'm sure someone more wise and older will chime in.
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Old 06-02-2010, 02:37 PM   #4
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Default Re: GSXR 600 Build frame up

Go back and read EZ600rr's thread about his sprocket set up.He's getting around 50 I think with his set u p.Just a thought.He has worked out a lot of the headaches.I know my next one will be that way.
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Old 06-02-2010, 03:44 PM   #5
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Default Re: GSXR 600 Build frame up

thx... for the valuable info on where to get stuff. I am still undecided as to going the sprocket route with high speed gears or the CVT route with high speed gears....

I am leaning to the CVT because its like an automatic and more like a golf cart. ... just do not know how well it will function with high speed or the stock gearing. I would hate to have a cart that just bogs down because of the nature of the MC engine and its internal gearing/clutching desgin being one of high top speed with no low end torque to cut up with.

What I want is a useable cart to put put with but also tear up the pavement if I need or want to. I am trying to find the best application for the MC engine to the golf cart transaxle when we know t hat the MC engine is geared high to be used with very high rpms and has very little low end torque power. To find the best application seems like trial and error. I wish someone on here would have done the CVT with high speed gears so that I could make up my mind!!! lol

The sprocket route requires contstant shifting and that could end up causing diff failure down the road? Personally, I do not really like the contstant need to shift, especailly if someone else uses my cart. But if that is the best way to get the best results, I guess I may have to just get used to shifting?
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Old 06-02-2010, 04:31 PM   #6
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Default Re: GSXR 600 Build frame up

I wouldn't use a cvt for a high reving 100hp motor. unless u steal clutches from a sled. but then you'd need to find a gear to leave the transmission in. and i think it would be ridiculously hard to pick a gear that will still have some bottom end power and top speed.

Do you have any experience driving sports quads? I mx race a yfz450. it's so easy to get used to shifting. and ALOT funner. I guess i have sort of a biased opinion, im really not into automatics for toys as it requires no skill. nothings funner then a high reving engine that u can hold in a gear.

You also must not have much experience on sport bikes, cause you said it has no low end torque. But It will have ALOT more tq then your stock cart engine
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Old 06-02-2010, 09:21 PM   #7
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Default Re: GSXR 600 Build frame up

Been having race dirt bikes since i was 10, 3 wheelers, 4 wheelers both utility and racing, street bikes and race bikes. I certainly know my way around toys and how to shift anything... grew up on a farm driving tractors, combines...u name it I drove it.

The point I was trying to make is that the CVT would give more of a feel of a golf cart compared to the clutch and gears and would be much more user friendly no matter who is trying to drive it.

I do stand by my point that these type MC (gsxr) engines and the like are NOT designed for lots of low end torque, quite the opposite, where they perform amazingly strong at medium and higher rpms.

I do agree that the clutch and gears gives a increased ability to stay in the power band, but I am uncertain that the diff could hold up to so much clutching and torque all the time?

If I go CVT I would definitely use TOM's clutch rated for 100 or more hp... all steel internals, but the problem for me is that no-one has done that setup yet with the high speed gears to know how it performs . I was also wondering if you could shift the MC to a higher gear on the fly usiing the CVT? Really you could use 1st or 2nd gear for putting around and 4th 5th and 6th for higher speeds giving you a lot of options for use?

Do not know enough aboout it to know if those things are even possible.
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Old 06-03-2010, 12:33 AM   #8
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Default Re: GSXR 600 Build frame up

So your wanting to do both then, have a clutch, but still have to shift.
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Old 06-03-2010, 07:11 AM   #9
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Default Re: GSXR 600 Build frame up

I am just looking for ideas and the CVT would require minimal shifting if any. More like choosing the right gear and if it perfroms well you would NOT have to shift.... but having the option to shift to a higher or lower gear just gives more options for driving.

It seems like the chain sprocket with clutch shifting is the way I will go for now because I cannot get enough info and/or real time advice from expereince with the CVT with a MC engine in a cart with a transaxle. I would almost have to drive one with a CVT and high speed gears to be able to know if it is something worth investing that kind of money in.

I figure the chain and sprocket with high speed gears is the cheapest and quickest fix for now and I could always switch to a CVT later if I hate it.

If 1st gear has some some real low end power and I can still get 50 MPH out of it in 6th gear, I may like it that way. What I am not going to like is having to ride the clutch to take off on 1st , no low end power and NOT be able to put around in it.

My hesitation on this decision is caused by hating to do things twice and the money it cost when you do.
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Old 06-03-2010, 12:58 PM   #10
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Default Re: GSXR 600 Build frame up

WHO HAS THE PART NUMBER to order the 11 tooth sprocket form dennis kirk that slips onto the rear diff?
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