It is currently Thu Jul 29, 2021 5:11 am



Post new topic Reply to topic  [ 143 posts ]  Go to page 1, 2, 3, 4, 5 ... 8  Next
Author Message
 Post subject: YerfDog IRS conversion, 200cc (Edit, 300cc) engine
PostPosted: Mon Apr 26, 2010 6:26 pm 
Offline
Buggified
User avatar

Joined: Tue Jan 20, 2009 10:47 pm
Posts: 645
Location: Goldsboro, North Carolina
Well I guess it's started and I need to post a thread about it. Picked this up Saturday afternoon https://www.buggynews.com/viewtopic.php?f=20&t=21690. It's really a piece of sh%t, so I've named it The POS. It has even more issues than I was aware, more rust than I thought and it has some cracked welds and one of the front bars has a crack almost all the way around the diameter of the bar. They had welded the front suspension bulkhead to the frame from underneath, I checked to see if the top had been welded but where they welded it could not be seen from overhead. After some time today with a sawzaw, grinder, cut off saw, air hammer and some other tools I have it where I can work with it.

This will be a YerfDog GX150 basic chassis combined with the rear frame section of the Scrambler 2 plans. So, it will have Independent Rear Suspension with double a arms and halfshafts (about 10-12 inches of travel). I will be installing a 1988 Honda TRX200SX 200cc engine with auto clutch, 5 speed trans with reverse (will now be a TRX300EX, manual clutch 5 speed with reverse). It will have a welded rollcage to replace the bolt on unit.


Attachments:
IMG_5438.JPG_thumb.jpg
IMG_5438.JPG_thumb.jpg [ 225.82 KiB | Viewed 16172 times ]
IMG_5457.JPG_thumb.jpg
IMG_5457.JPG_thumb.jpg [ 95.26 KiB | Viewed 16172 times ]
IMG_5458.JPG_Thumb.jpg
IMG_5458.JPG_Thumb.jpg [ 111.09 KiB | Viewed 16172 times ]
IMG_5448.JPG_thumb.jpg
IMG_5448.JPG_thumb.jpg [ 245.15 KiB | Viewed 16172 times ]
IMG_5454.JPG_thumb.jpg
IMG_5454.JPG_thumb.jpg [ 260.31 KiB | Viewed 16172 times ]

_________________
Richard Holden



2004? YerfDog GX-150 3206 Personized
Too many mods to list here.

200? YerfDog GX-150 3206 (The POS) IRS, 200SX (NOW 300EX) engine conversion


Last edited by bandit1100 on Fri Mar 01, 2013 6:14 pm, edited 3 times in total.
Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Mon Apr 26, 2010 9:18 pm 
Offline
Buggified
User avatar

Joined: Tue Jan 20, 2009 10:47 pm
Posts: 645
Location: Goldsboro, North Carolina
Some more.


Attachments:
IMG_5462.JPG_thumb.jpg
IMG_5462.JPG_thumb.jpg [ 213.91 KiB | Viewed 16162 times ]
IMG_5464.JPG_thumb.jpg
IMG_5464.JPG_thumb.jpg [ 186.32 KiB | Viewed 16162 times ]
IMG_5465.JPG_thumb.jpg
IMG_5465.JPG_thumb.jpg [ 188.81 KiB | Viewed 16162 times ]
IMG_5467.JPG_thumb.jpg
IMG_5467.JPG_thumb.jpg [ 191.51 KiB | Viewed 16162 times ]

_________________
Richard Holden



2004? YerfDog GX-150 3206 Personized
Too many mods to list here.

200? YerfDog GX-150 3206 (The POS) IRS, 200SX (NOW 300EX) engine conversion
Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Mon Apr 26, 2010 9:24 pm 
Offline
Buggified
User avatar

Joined: Thu May 28, 2009 7:38 am
Posts: 503
Location: Ontario, Canada
Wow, what did they do, drop it off the back of a truck???
Looking forward to the build thread =D>

Mark


Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Thu Apr 29, 2010 6:50 pm 
Offline
Buggified
User avatar

Joined: Sun Mar 21, 2010 6:06 am
Posts: 609
Location: Grovetown, GA
Ditto everyone else....this is gonna get good!

_________________
TCOB...

kliff

Yerfi I
another-yerfie-revival-t24328.html

The "Puddle Jumper"
the-rocky-road-to-building-a-bandit-t22518.html


Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Sun May 02, 2010 9:28 am 
Offline
Buggified
User avatar

Joined: Wed Jul 30, 2008 2:39 pm
Posts: 682
Location: McHenry County Illinois
Looking good so far...... :D

_________________
You know Jesus wasn't married. No wife lets you come home after three days with the excuse
"I was dead".

2005-Yerfdog 4209
2005-Joyner 650ss

LEAGUE DIRECTOR,
NORTH Central BUGGY ASSOCIATION

http://[email protected]


Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Mon May 10, 2010 11:20 pm 
Offline
Buggified
User avatar

Joined: Tue Jan 20, 2009 10:47 pm
Posts: 645
Location: Goldsboro, North Carolina
Theo, do you know if the hubs will press apart to machine the flange down? The hubs I bought are much more beefier than the ones pictured, I don't even have enough clearance on the backside to remove the studs. :twisted:


Attachments:
diff0151.jpg
diff0151.jpg [ 74.48 KiB | Viewed 16063 times ]

_________________
Richard Holden



2004? YerfDog GX-150 3206 Personized
Too many mods to list here.

200? YerfDog GX-150 3206 (The POS) IRS, 200SX (NOW 300EX) engine conversion
Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Wed May 19, 2010 6:24 am 
Offline
Buggified
User avatar

Joined: Sun Mar 21, 2010 6:06 am
Posts: 609
Location: Grovetown, GA
Any up=dates Richard?

_________________
TCOB...

kliff

Yerfi I
another-yerfie-revival-t24328.html

The "Puddle Jumper"
the-rocky-road-to-building-a-bandit-t22518.html


Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Thu May 20, 2010 8:34 am 
Offline
Buggified
User avatar

Joined: Tue Jan 20, 2009 10:47 pm
Posts: 645
Location: Goldsboro, North Carolina
As a matter of fact.....Yes.

Played with the mock frame mounting the engine on the bottom rail to (A) lower the CG, (B) to try to get the engine to mount further back (as much as possible) to try to shorten up the front legs of the frame so I can get the wheelbase as close to stock as possible and (C) to help out the chain angle. The down angle is such that I will have to use an idler sprocket to keep the chain off engine case, was planning to use an idler anyway to keep chain tension so no big deal.
Outcome? Didn't work, engine wouldn't mount back where it was on the top rail.

So, cut the tubes and welded up a new frame from thicker tubes. After everything was squared up I tacked it into place last night. While I was at it I cut off the stock swing arm brackets and all the bolt on brush guard mounts.
Was thinking about the rear brake setup, I had an old brake disc from a CBR600 in a box left over from another project. So I cut out a piece of 1/4" plate, checked it in the lathe and made an adaptor hub. Picked up a CBR rear caliper off EBay for $10, it came in yesterday.

I also cut out new a arm mounts and hub carriers out of 3/16” material, that’s what the Scrambler plans call for, I had made the ones for the mockup out of ¼”. Just some material I had lying around.


Attachments:
IMG_5487.JPG
IMG_5487.JPG [ 3.44 MiB | Viewed 16002 times ]
IMG_5491.JPG
IMG_5491.JPG [ 3.24 MiB | Viewed 16002 times ]
IMG_5489.JPG
IMG_5489.JPG [ 2.88 MiB | Viewed 16002 times ]
IMG_5494.JPG
IMG_5494.JPG [ 3 MiB | Viewed 16002 times ]
IMG_5472.JPG
IMG_5472.JPG [ 2.7 MiB | Viewed 16002 times ]
IMG_4795.JPG
IMG_4795.JPG [ 702.96 KiB | Viewed 16002 times ]

_________________
Richard Holden



2004? YerfDog GX-150 3206 Personized
Too many mods to list here.

200? YerfDog GX-150 3206 (The POS) IRS, 200SX (NOW 300EX) engine conversion
Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Thu May 20, 2010 4:51 pm 
Offline
Buggified
User avatar

Joined: Tue Jan 20, 2009 10:47 pm
Posts: 645
Location: Goldsboro, North Carolina
Yea, I don't think this one is going to fit in the back of my truck, length or width. I have a 100 gallon auxiliary fuel tank in the front of the bed and the other Yerf's rear tires sit on the tailgate with the fronts on the tank.
The front most likely will be a modified stock. The stock rear axle width flange to flange is 35", this will be more like 48"-50". So I'll widen out the front to match the rear, or close to it. I was thinking about lengthening the front arms (actually building new arms, same design, better material) and having longer shocks. 300 or 400EX front spindles or might just use the brakes and hubs off the 200SX sense I have them, but they are drum. :?

_________________
Richard Holden



2004? YerfDog GX-150 3206 Personized
Too many mods to list here.

200? YerfDog GX-150 3206 (The POS) IRS, 200SX (NOW 300EX) engine conversion


Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Fri May 28, 2010 9:23 pm 
Offline
Buggified
User avatar

Joined: Tue Jan 20, 2009 10:47 pm
Posts: 645
Location: Goldsboro, North Carolina
Managed to get some more done this week. Finish welded the rear frame section, the new hub carriers and a arm mounts to the frame. Axle bearing mounts are tacked in, I don't like how they are sitting so I'm going to play with them some more. I bought an idler sprocket from Eric Buell motorsports, it's a replacement part for a race chain drive conversion on the 1125R and XB bikes. Only 420 chain idler sprocket I could find, but when it came in I discovered it's made from a nylon or some type of plastic material. I don't think it will last in the environment I'll subject it to, so I'm going to try to return it. Will pick up a #50 sprocket from AgriSupply tomorrow on the way out to Charlotte (going to the Coke 600!), I'll have to chuck it in the lathe and turn it down a bit to fit the 420 chain (#50 or 530 if you prefer, is wider than the 420, but same pitch). The fourth a arm was still cooling from welding it up when I took the pics. Will have to fab up a caliper mount for the CBR caliper as well as the idler sprocket mount. I'll need to turn up 8 more a arm bushings on the lathe as well. I think I found a great place for a battery also. 8)
Supposed to go look at a set of aftermarket sport seats (BOMZZ, I think was the brand name) when I get back into town that were in a sport compact, he wants $150 or best offer. Need to get my junk ready to roll out tomorrow. :D


Attachments:
IMG_5526.JPG
IMG_5526.JPG [ 3.42 MiB | Viewed 15018 times ]
IMG_5527.JPG
IMG_5527.JPG [ 2.96 MiB | Viewed 15018 times ]
IMG_5528.JPG
IMG_5528.JPG [ 3.34 MiB | Viewed 15018 times ]
seats.jpg
seats.jpg [ 20.29 KiB | Viewed 15018 times ]

_________________
Richard Holden



2004? YerfDog GX-150 3206 Personized
Too many mods to list here.

200? YerfDog GX-150 3206 (The POS) IRS, 200SX (NOW 300EX) engine conversion
Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Fri May 28, 2010 9:37 pm 
Offline
Admin
User avatar

Joined: Wed Nov 28, 2007 2:21 am
Posts: 17878
Images: 24
Location: Pacific NW
Are you sure about the chain? I thought the difference between 420 and 520 chain was the pitch while the width was the same. 520 and 530 chain have the same pitch, but the 520 is narrower.

_________________
09 Joyner SandViper 250
57 VW Transport 1200 (Buggified)


Top
 Profile Personal album  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Fri May 28, 2010 11:04 pm 
Offline
Buggified
User avatar

Joined: Tue Jan 20, 2009 10:47 pm
Posts: 645
Location: Goldsboro, North Carolina
You are correct sir, I mispoke. The 200SX takes a 520 chain not the 420 that I spewed forth.

_________________
Richard Holden



2004? YerfDog GX-150 3206 Personized
Too many mods to list here.

200? YerfDog GX-150 3206 (The POS) IRS, 200SX (NOW 300EX) engine conversion


Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Fri May 28, 2010 11:59 pm 
Offline
Buggy Addict
User avatar

Joined: Sun Jan 27, 2008 1:50 am
Posts: 4945
Images: 6
Location: Las Vegas, NV
Man Richard that set up looks really nice. What will the wheelbase be after the modification, and what is it stock?

Greg

_________________
07 "Purple Xtract" a mutant Viper 600 f4i, FOA shocks
06 Dune w/cn250/IRS SOLD
Scrambler w/cbr 600
08 Trooper 2


Top
 Profile Personal album  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Sat May 29, 2010 5:40 am 
Offline
Buggified
User avatar

Joined: Tue Jan 20, 2009 10:47 pm
Posts: 645
Location: Goldsboro, North Carolina
Looks as if it'll be about a foot longer. I'll know more when I get around to working the front. I'll measure the stock wheelbase Yerf when I get back into town.

_________________
Richard Holden



2004? YerfDog GX-150 3206 Personized
Too many mods to list here.

200? YerfDog GX-150 3206 (The POS) IRS, 200SX (NOW 300EX) engine conversion


Last edited by bandit1100 on Tue Jun 01, 2010 10:38 am, edited 1 time in total.

Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Sat May 29, 2010 10:24 am 
Offline
Buggy Addict
User avatar

Joined: Sun Jan 27, 2008 1:50 am
Posts: 4945
Images: 6
Location: Las Vegas, NV
Hey Richard you seem to be more experienced than me at this, so I'll just throw it out. Have you incorporated shock absorbing motor mounts? I had a hard time figuring out what to do, so I skiipped it, after 2hrs of seat time, I wish I would've put more thought into it.

Greg

_________________
07 "Purple Xtract" a mutant Viper 600 f4i, FOA shocks
06 Dune w/cn250/IRS SOLD
Scrambler w/cbr 600
08 Trooper 2


Top
 Profile Personal album  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Sat May 29, 2010 1:52 pm 
Offline
Buggified
User avatar

Joined: Tue Jan 20, 2009 10:47 pm
Posts: 645
Location: Goldsboro, North Carolina
To quell engine vibration? Hadn't thought it would be a problem. I had just planned to fab up some that used the stock mounts of the quad. Might have to rethink things a bit. We are now in Charlotte. :D

_________________
Richard Holden



2004? YerfDog GX-150 3206 Personized
Too many mods to list here.

200? YerfDog GX-150 3206 (The POS) IRS, 200SX (NOW 300EX) engine conversion


Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Sat May 29, 2010 9:00 pm 
Offline
Buggy Addict
User avatar

Joined: Sun Jan 27, 2008 1:50 am
Posts: 4945
Images: 6
Location: Las Vegas, NV
ChuckOrlando wrote:
Looks real good bro. How much money do you think you have tied up in the spool, arms, spindles, and axles?

Greg is your motor mounted metal to metal?


Yeah Chuck it's mounted metal to metal sort of I put some rubber washer on, when I painted. When I was doing the conversion I kept looking at the Joyner and could figure out a way to mimick the mounting plate. The problems were no mounting holes on the bottom, and that huge gearbox. It's the vibration to the floor pan that get tiresome. I bought a rubber mat haven't attached it yet.

Richard I know the Joyner and Kinroad (irs) use the same principle. What about the HH250 Chuck?

Greg

_________________
07 "Purple Xtract" a mutant Viper 600 f4i, FOA shocks
06 Dune w/cn250/IRS SOLD
Scrambler w/cbr 600
08 Trooper 2


Top
 Profile Personal album  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Sun May 30, 2010 8:07 am 
Offline
Buggified
User avatar

Joined: Sun Mar 21, 2010 6:06 am
Posts: 609
Location: Grovetown, GA
Looking good Richard! Keep it up. DP this Fall...

_________________
TCOB...

kliff

Yerfi I
another-yerfie-revival-t24328.html

The "Puddle Jumper"
the-rocky-road-to-building-a-bandit-t22518.html


Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Sun May 30, 2010 11:59 pm 
Offline
Buggy Enthusiast
User avatar

Joined: Sat May 29, 2010 11:35 pm
Posts: 127
Location: wash c.h ohio
this is looking good!! =D> this is something like what i have always thought about doing. even thou you seem to know alot more about this than i would. still maybe one day i will give it a go :D


Top
 Profile  
 
 Post subject: Re: YerfDog IRS conversion, 200cc engine
PostPosted: Mon May 31, 2010 2:08 am 
Offline
Buggy Addict
User avatar

Joined: Sun Jan 27, 2008 1:50 am
Posts: 4945
Images: 6
Location: Las Vegas, NV
It's looking real good. I converted my Dune, the hardest part is making the first cut.

dune-irs-input-sugg-welcome-pls-t19173.html

Greg

_________________
07 "Purple Xtract" a mutant Viper 600 f4i, FOA shocks
06 Dune w/cn250/IRS SOLD
Scrambler w/cbr 600
08 Trooper 2


Top
 Profile Personal album  
 
Display posts from previous:  Sort by  
Post new topic Reply to topic  [ 143 posts ]  Go to page 1, 2, 3, 4, 5 ... 8  Next


Who is online

Users browsing this forum: No registered users and 0 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Search for:
Jump to:  
cron
Powered by phpBB © 2000, 2002, 2005, 2007 phpBB Group

blackLevel designed by GrafsS



phpBB SEO
© Buggynews.com - All Rights Reserved