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rotax 617 and long travel conversion
http://www.pilotodyssey.com/PO/viewtopic.php?f=5&t=14265
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Author:  B S [ Sun Dec 21, 2014 2:05 am ]
Post subject:  Re: rotax 617 and long travel conversion

jknarfal wrote:
that's my next purchase I think. As soon as funding becomes available Id like to do that. Did you have the 350 with the longtravel rear and the aftermarket gear box?

No
Just the stock rear end with works shocks

Author:  jknarfal [ Sun Dec 21, 2014 4:40 pm ]
Post subject:  Re: rotax 617 and long travel conversion

I'm looking to build long travel rear with cvs. I was thinking of setting it up like the pilot has in the rear. Possibly even using the pilot parts as well. There's not a lot of long travel rear 350s out there apparently. I haven't found much info on them.

Author:  jknarfal [ Tue Dec 23, 2014 10:20 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Found some more time to work on this project. Dressed up the parking brake handle a bit. I'll make I new vinyl cover for it. I will also do the shifter.

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Author:  jknarfal [ Thu Dec 25, 2014 8:08 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Did some work on the shifter. The rubber boot was bad and I have had issues with it rusting stuck before. The plastic was also Sun beaten. I added a sleeve on the bottom so that the knob overlaps and hopefully help keep moisture and debris out of the shaft.

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Author:  hoser [ Thu Dec 25, 2014 9:23 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Nice work! :-)

Author:  bugeye59 [ Wed Dec 31, 2014 11:14 pm ]
Post subject:  Re: rotax 617 and long travel conversion

jknarfal wrote:
Stupid eBay


That canister isn't vented?
Your gonna add a vent right?

Author:  jknarfal [ Thu Jan 01, 2015 11:32 am ]
Post subject:  Re: rotax 617 and long travel conversion

The canister I sent back because they sent me the wrong one and then they never sent me another one. I'll have to order one from another source. But no I believe it was not vented because it is actually a oil catch and is designed to be mounted upside down. The cap on top is actually just a drain. But if you flip it over and add a vent it would work well for this purpose.

Author:  jknarfal [ Thu Jan 01, 2015 6:05 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Got some more work done on my exhaust. Finally built all the mounts for the pipe and silencer. The silencer will receive a turn out so that it doesnt dump onto the frame. It will also get re-polished

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Author:  B S [ Mon Jan 05, 2015 3:24 am ]
Post subject:  Re: rotax 617 and long travel conversion

so whats the plan with the rear LT?

Author:  jknarfal [ Mon Jan 05, 2015 11:02 am ]
Post subject:  Re: rotax 617 and long travel conversion

Well I ordered a cv shaft. From a Polaris ranger midsize front shaft. From what I found it should be just about right. I plan on building suspension similar to the pilots. If it works for those itll work for me. I've been looking at side by sides for suspension ideas but there mostly just double A arm and I've seen a lot of pics of them broken. What size heim joints do they use?

Author:  DMoneyAllstar [ Mon Jan 05, 2015 12:10 pm ]
Post subject:  Re: rotax 617 and long travel conversion

I would say on a single-seater buggy under 750-lbs you could run 5/8" chromoly on 1/2" bolt and be fine beating the p!ss out of the rig. If there's only one upper & lower heim on the rear carrier (rather than a pair), maybe bump it up to 3/4" there if you're worried. Or if you're buying cheaper "economy grade" parts, definitely go bigger. IMO, of course. :-)

I used "economy grade" 5/8-on-1/2 heims on my FL350 rear upper links and haven't had any issues. But this is trail riding -- nothing too rocky, no woops, no jumps, and stock powerplant.

Author:  B S [ Mon Jan 05, 2015 1:36 pm ]
Post subject:  Re: rotax 617 and long travel conversion

oops

Author:  DMoneyAllstar [ Mon Jan 05, 2015 2:42 pm ]
Post subject:  Re: rotax 617 and long travel conversion

B S wrote:
just some info for your build


when you run a belt run the pilot belt it worked the best when i had my odyssey



What is the Pilot belt spec width anyways? I know my FL470 Engine configuration will not put the clutch the exact same distance from the trans as the stock Engine, so really only the width mattered.

Author:  B S [ Mon Jan 05, 2015 2:45 pm ]
Post subject:  Re: rotax 617 and long travel conversion

DMoneyAllstar wrote:
B S wrote:
just some info for your build


when you run a belt run the pilot belt it worked the best when i had my odyssey



What is the Pilot belt spec width anyways? I know my FL470 Engine configuration will not put the clutch the exact same distance from the trans as the stock Engine, so really only the width mattered.

sorry that was for your build D$* i got the 2 threads confused lol

Author:  jknarfal [ Mon Jan 05, 2015 4:45 pm ]
Post subject:  Re: rotax 617 and long travel conversion

I have kept with all metric hardware so far. I found 14mm heims reasonably priced. I believe the cv shaft I ordered is about 18" not including splined shafts at ether end. I emailed FARR asking about his set up but he never replied. Over the weekend I machined a spacer for the skidoo clutch so that it matches the with of the stock 350 belt.

Author:  bullnerd [ Mon Jan 05, 2015 5:36 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Theres a thread here somewhere with some good info for a possible rear setup.

Author:  jknarfal [ Mon Jan 05, 2015 11:57 pm ]
Post subject:  Re: rotax 617 and long travel conversion

I've looked around but I haven't found much info. If anyone knows of any good rear suspension builds please post a link

Author:  DMoneyAllstar [ Tue Jan 06, 2015 3:49 am ]
Post subject:  Re: rotax 617 and long travel conversion

jknarfal wrote:
I've looked around but I haven't found much info. If anyone knows of any good rear suspension builds please post a link


We were hashing out some ideas on this thread, but just thoughts...

http://www.pilotodyssey.com/PO/viewtopic.php?f=1&t=13602

The tough part is the hoops you have to jump through if keeping the stock fl350 gearbox. The suspension is either trailing arm or a-arm. Simple. But adding a conversion hub to the output shaft for another axle type adds width, there are clearance issues with the brake rotor and gearbox housing, going too bulky may create braking hazards, angular limitations on stock u-joints, and using a stronger axle moves the weak link inside the gearbox instead of at the u-joint. Jeffco and rpm boxes arent cheap. Polaris sportsman gearboxes are too huge and are 4x4. Drakart, revolt, etc gearboxes are a rare find and so are replacement parts. Hell, even Honda made a whole new buggy as a solution! lol

Why is Dan on here at 3am??? Got my son in my other arm feeding him a bottle, lol.

Author:  B S [ Tue Jan 06, 2015 12:18 pm ]
Post subject:  Re: rotax 617 and long travel conversion

jknarfal wrote:
I have kept with all metric hardware so far. I found 14mm heims reasonably priced. I believe the cv shaft I ordered is about 18" not including splined shafts at ether end. I emailed FARR asking about his set up but he never replied. Over the weekend I machined a spacer for the skidoo clutch so that it matches the with of the stock 350 belt.

Farr never emails back or if he does its weeks later :shock: :shock: :shock:

Author:  jknarfal [ Tue Jan 06, 2015 1:38 pm ]
Post subject:  Re: rotax 617 and long travel conversion

The axle set up that Farr is using with the Polaris shafts looks to be a simple but effective way to convert the 350 box to cv. Having the final drive shaft machined for internal splines should allow for plenty of clearance using the Polaris shafts. Plus it will move the pivot point of the shaft inward allowing for more travelof the axle. When my shaft arrives ill post pics and specs on it.

Author:  DMoneyAllstar [ Tue Jan 06, 2015 3:18 pm ]
Post subject:  Re: rotax 617 and long travel conversion

jknarfal wrote:
The axle set up that Farr is using with the Polaris shafts looks to be a simple but effective way to convert the 350 box to cv. Having the final drive shaft machined for internal splines should allow for plenty of clearance using the Polaris shafts. Plus it will move the pivot point of the shaft inward allowing for more travel of the axle. When my shaft arrives ill post pics and specs on it.


Would be fabulous to see it done. So you want to modify the final shaft to go from male to female on the stock gearbox? That doesn't sound easy or cheap. I think Farr was going to do something like that, but re-create the gearbox housing while utilizing the rest of the stock gearbox's guts so as to accommodate a different final shaft config (male axle end with female output shaft).

OMG...its a trans-gender! :shock: LOL

Author:  DMoneyAllstar [ Tue Jan 06, 2015 3:43 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Here is the thread about FL350 axles, and on the 1st page these is a FL350 retrofitted to CV's.

http://www.pilotodyssey.com/PO/viewtopic.php?f=1&t=9767

The width from inner CV to inner CV is huuuge.

Author:  B S [ Tue Jan 06, 2015 7:13 pm ]
Post subject:  Re: rotax 617 and long travel conversion

DMoneyAllstar wrote:
Here is the thread about FL350 axles, and on the 1st page these is a FL350 retrofitted to CV's.

http://www.pilotodyssey.com/PO/viewtopic.php?f=1&t=9767

The width from inner CV to inner CV is huuuge.

there is actually another thread for axles info

Author:  jknarfal [ Tue Jan 06, 2015 10:44 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Does anyone know how long a pilot shaft is? I read somewhere a long travel pilot shaft was 17.5" long not including the splined shafts. I believe the ranger shaft I ordered is 18". I don't want to get too wide. I set the front suspension up to be as narrow as possible with the trx A arms. But I guess I can always get wider trx arms if I had to. I plan on running this mostly in the sand ( and up and down the street in front of my house to piss the neighbors off). I have two other stock 350s i use in the dirt and in rocky areas. For the amount of time and money I am putting into this I wouldn't want to trash it. But I definitely want it set up right.

Author:  jknarfal [ Thu Jan 08, 2015 2:39 am ]
Post subject:  Re: rotax 617 and long travel conversion

My caliper was pirty bad. The hanger pin was stripped out and had to be drilled and extracted. The piston was seized. I received the material I had ordered today so I machined a new one piece stainless steel piston. It fits very nicely I'm pleased with how it turned out.

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