Another "Franken-Project" from yours truly... - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 23 (permalink) Old 10-31-2014, 09:54 AM Thread Starter
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Another "Franken-Project" from yours truly...

Thru the time of ownership and all the mods I have done on the Vaq I had the desire to tackle another project, and this kinda goes waaaay back to the beginning.

Back in 2011 when the stock rr tire wore out I replaced it with a larger and also "taller" rr tire, a 180/70. I liked how that tire altered the gear ratio and the lowered engine rpm out on the hiway. Only drawback was that since the skoot was at the beginning of it's development power-wise the taller tire somewhat reduced the acceleration. Add onto that was the 7200 ml lifespan and after that tire wore out it was a search for a higher mileage tire.
The Commander 2's have given me good life, but from new to worn out the circumference of the tire changes so much that the affect is noticeable. Too much shifting in town and elevated engine rpm, specially on the hiway. I could notice the change as soon as the tire had 6000 mls, and now at 7000 with the start of a flat spot it's getting more noticeable. And irritating.

With the recent intake mods and new mapping the power and quality of power has improved noticeably and the desire to "fix" this gearing situation came to fruition. For many months I had been researching altering pulley sizes, first to a larger front pulley. That was deemed not possible to insufficient clearance around the front pulley, so a smaller rr pulley was my goal. All the 1700's use the same size, and other Kawi's had pulley sizes not within my goal of tooth count of 2-4teeth smaller.

First order was to figure out the belt situation. Did Kawi and Yami use the same style belt? Yes they did. I was gonna need a shorter belt to work with the smaller rr pulley, was that available? Yes. It was a belt listed for Harleys and with further research I found most skoots use belts with the same pitch. This was a good thing for sure and could of been a deal breaker.

I expanded my search to include other brands and found Yamaha's use a 70 tooth rr pulley, 2 teeth smaller. Since I did not want the skoot down I found a used Kawi rr pulley/pulley hub on eBay and bought it, that way I could whittle on the hub as needed without sacrificing mine. I eventually found a Yamaha pulley/hub assembly that had been taken off a new skoot that got some custom wheels. It had absolutely no wear, was basically brand new. So with a new shorter belt, a new stock front pulley, a smaller rr pulley and a spare Kawi pulley hub the fun was about to begin...

RACNRAY

"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"

Last edited by RACNRAY; 11-01-2014 at 07:50 AM.
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post #2 of 23 (permalink) Old 10-31-2014, 10:22 AM Thread Starter
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Side to side comparison of the Kawi and Yami parts, not a good start, Kawi on the rite. Amount of offset way too much on the yami part...



Comparing the hubs, another no go situation. Even tho both hubs were 6 fingers the diameters were wrong, so utilizing the yami hub was not possible.



This brought in the next aspect, different bolt patterns for the pulleys...



So the plan was gonna include the appropriate machining to fit the yami pulley to the kawi hub...and then welding it all together.

The yami pulley getting it's inner bore centered on my mill so I can bore it larger...



The beginning of the boring process...



Getting closer...



Due to the pulley teeth being offset to the hub via where the spokes attached to the pulley I was gonna have to mount the pulley "backwards" onto the hub to help make up for way too much offset in the yami pulley. Here is the machining taking away material to reduce some of the offset, which left only .190" to machine off the kawi hub...



Finished inner bore and new mounting surface...



MORE TO COME...

"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"

Last edited by RACNRAY; 11-01-2014 at 08:29 AM.
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post #3 of 23 (permalink) Old 10-31-2014, 10:41 AM Thread Starter
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2 views of the yami pulley sittin on the kawi hub...





Rough centering of the kawi hub on the rotary table...



Which made it easier and quicker to accomplish the final centering based on the original machining of the 6 stand-offs ...



Now the beginning machining of the needed .190" to arrive at the correct offset...



New mounting surface all machined and using a ball end mill to machine a chamfer around the hub's circumference for good weld penetration...



The pulley and hub glass beaded...



And set in place. You will notice how ugly it's gonna look because of the necessity to mount the yami pulley backwards on the kawi hub, exposing the inside mounting area of the yami pulley...



BUT...I gotta fix for that!!!

"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"

Last edited by RACNRAY; 11-01-2014 at 07:53 AM.
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post #4 of 23 (permalink) Old 10-31-2014, 10:49 AM
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dear Franky Stein, yor like that rich kid on the block. its no fair you get all the neat toys to play with..
the rest of us have to sit in the dirt and pretend with cardboard boxes.. we got out of yor trash bin. poncho



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post #5 of 23 (permalink) Old 10-31-2014, 10:56 AM Thread Starter
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The whole assembly clamped together for it's trip to the welder...



And welded together...



I had the outer area welded also to increase strength...



Gonna have to make a plate to cover that ugly area, here is what I started with, painted for the contrast machining...



The basic look and using a ball end mill to chamfer the edges...



The plate with it's mounting holes drilled in and ready to be separated from the plate...



And cutting it out...



Machining the welds on the hub flat to allow the cover plate to sit properly...


"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"

Last edited by RACNRAY; 11-01-2014 at 08:31 AM.
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post #6 of 23 (permalink) Old 10-31-2014, 11:01 AM Thread Starter
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Quote:
Originally Posted by Poncho Villa View Post
dear Franky Stein, yor like that rich kid on the block. its no fair you get all the neat toys to play with..
the rest of us have to sit in the dirt and pretend with cardboard boxes.. we got out of yor trash bin. poncho
SORRY DUDE..I am NOT even close to being that "rich kid on the block". I have paid my dues over 38 years in the South Florida m/c industry. I have worked my ASS off doin nothing else but striving to be better. I HAVE NOT "gotten all the neat toys to play with" without tremendous debt and that above mentioned hard work.

RACNRAY

"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"
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post #7 of 23 (permalink) Old 10-31-2014, 11:18 AM Thread Starter
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The plate bolted down...



The whole assembly painted with PJ1 satin engine paint and baking in the South Fla sun...



Saw these kinda ugly casting dimples so I decided to machine them for more of a contrast effect...



Everything ready for install...



Installed on the wheel...



Installed on the skoot...



The rear axle now sits about 3/16" further forward and that little difference does help a bit in ease of turning.

BUT...last nites ride results and what I was lookin for has been mostly met. I can run each gear longer which equates to more mph b4 shifting, the engine is definitely turning less rpm out on the hiway, tho the speedo/odo is reading slower. Gonna ride tonite with a GPS to see what the new nmbrs are. The engine feels less "frantic" and still pulls real hard. I am happy with the results.

BEHOLD..."FRANKEN-PULLEY!!!"

RACNRAY

"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"

Last edited by RACNRAY; 11-01-2014 at 08:33 AM.
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post #8 of 23 (permalink) Old 10-31-2014, 12:22 PM
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Quote:
Originally Posted by RACNRAY View Post
SORRY DUDE..I am NOT even close to being that "rich kid on the block". I have paid my dues over 38 years in the South Florida m/c industry. I have worked my ASS off doin nothing else but striving to be better. I HAVE NOT "gotten all the neat toys to play with" without tremendous debt and that above mentioned hard work. RACNRAY
rr, hope you know that was a joke.. most fellas can only dream of having access to all the "cool toys" machines. yes, nothing comes ez, there is no such thing as "free" unless of course yor prez is handing it out,, but then somebody had o pay for it? did not mean to rub you wrong. poncho



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post #9 of 23 (permalink) Old 10-31-2014, 02:37 PM Thread Starter
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Quote:
Originally Posted by Poncho Villa View Post
rr, hope you know that was a joke.. most fellas can only dream of having access to all the "cool toys" machines. yes, nothing comes ez, there is no such thing as "free" unless of course yor prez is handing it out,, but then somebody had o pay for it? did not mean to rub you wrong. poncho
OKEEDOKEE...thanx for the clarification.

RACNRAY

"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"
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post #10 of 23 (permalink) Old 10-31-2014, 04:12 PM
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You had me at "gearing"...
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