Phatmoto Rover 98cc build

[phatmotocat]

Howdy folks,

Just thought some may want to see my Rover 98 cc/belt conversion. It's still in progress and am waiting for new parts needed for the build to arrive. My new 98cc Coleman from gopowersports arrived Saturday. It looks great, even the box was in good condition. I already had a 30 series torque converter kit which I will be using most parts from, including the jack shaft, and pulleys. I called gopowersports to ask them which size belt is needed and they are sending me a new belt. Also, the TC kit only came with a 10 tooth #420 sprocket which won't work so ordered a new 10 tooth 415 sprocket,.. on order also. The first step was removing the old jack shaft and bearings. Next had to remove the bearings from the torque converter plate, be careful, these are to be installed in bike frame tube. Next was the cutting of two pieces of Super Strut found in the electrical supply. They are 13/16'' tall with slotted holes. These allow some flexibility in mounting the new engine.

 

[phatmotocat]

So the next issue I run into is installing drive pulley on engine shaft. I understand each engine may have slightly different tolerances where the spacer or washer rests against. I'm adding a sleeve to the 16 mm engine shaft for the 3/4'' pulley. In my case the pulley sticks out a bit too far. So I will need to machine the pulley down about an 1/8'' to better align the pulleys.

 

[Chainlube]

So the next issue I run into is installing drive pulley on engine shaft. I understand each engine may have slightly different tolerances where the spacer or washer rests against. I'm adding a sleeve to the 16 mm engine shaft for the 3/4'' pulley. In my case the pulley sticks out a bit too far. So I will need to machine the pulley down about an 1/8'' to better align the pulleys.

That's the nature of the beast. Every TAV I have used did that. Even on 212s. You'll end up with other alignment issues if you cut it. The bolt will hold it on.

 

[phatmotocat]

That's the nature of the beast. Every TAV I have used did that. Even on 212s. You'll end up with other alignment issues if you cut it. The bolt will hold it on.

Thanks for the clue. I was a bit concerned the shaft sleeve would be a weak point but since the bolt locks it in place makes me feel better about it. This TC kit I got came with no lock bolt for drive pulley. Another trip to hardware to get that. Thanks for the tip.

 

[Chainlube]

Thanks for the clue. I was a bit concerned the shaft sleeve would be a weak point but since the bolt locks it in place makes me feel better about it. This TC kit I got came with no lock bolt for drive pulley. Another trip to hardware to get that. Thanks for the tip.

Some of them are 5/16" and some are metric, know which one you have to get.

 

[phatmotocat]

Some of them are 5/16" and some are metric, know which one you have to get.

I will need to check my engine to see which one I have. I thought they were all 5/16'' but have to check. Thanks.

 

[phatmotocat]

Some of them are 5/16" and some are metric, know which one you have to get.

Looks like this Coleman has a 6M 1.0

 

[phatmotocat]

That's the nature of the beast. Every TAV I have used did that. Even on 212s. You'll end up with other alignment issues if you cut it. The bolt will hold it on.

The next issue I had to solve today was the exhaust. The predator pipe I bought would not clear the driven pulley so had to fabricate a new one. Hope to have completed Friday.

 

[phatmotocat]

That's the nature of the beast. Every TAV I have used did that. Even on 212s. You'll end up with other alignment issues if you cut it. The bolt will hold it on.

Exhaust is done and I'm exhausted myself. I cut the old pipe and had a friend weld it on the original manifold.

 

[Gordy]

Howdy folks,

Just thought some may want to see my Rover 98 cc/belt conversion. It's still in progress and am waiting for new parts needed for the build to arrive. My new 98cc Coleman from gopowersports arrived Saturday. It looks great, even the box was in good condition. I already had a 30 series torque converter kit which I will be using most parts from, including the jack shaft, and pulleys. I called gopowersports to ask them which size belt is needed and they are sending me a new belt. Also, the TC kit only came with a 10 tooth #420 sprocket which won't work so ordered a new 10 tooth 415 sprocket,.. on order also. The first step was removing the old jack shaft and bearings. Next had to remove the bearings from the torque converter plate, be careful, these are to be installed in bike frame tube. Next was the cutting of two pieces of Super Strut found in the electrical supply. They are 13/16'' tall with slotted holes. These allow some flexibility in mounting the new engine.

So the next issue I run into is installing drive pulley on engine shaft. I understand each engine may have slightly different tolerances where the spacer or washer rests against. I'm adding a sleeve to the 16 mm engine shaft for the 3/4'' pulley. In my case the pulley sticks out a bit too far. So I will need to machine the pulley down about an 1/8'' to better align the pulleys.

With the way you did the engine riser you might be able to get away with moving the engine over a bit to help with alignment. If that's not possible, you might be able to space the driven pulley over to lighn up better.