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 Post subject: FL350 "reloaded"
PostPosted: Tue Aug 26, 2014 4:28 am 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
Hi guys... here is my story... I used to have a Drakart. Bought the basic "sports" model from Alain, dropped the Kawasaki 750 V Engine, and swapped it for a Ninja 636.... It was SWEET... and then I sold it.... I miss the darn thing..

A few months back I was able to recover an FL350, I used to own, waaay back..

As I started to fix it again, I remembered the whole ordeal... and why I sold the thing in the first place, and forgot about it...

I decided to put some LIFE back into the FL350, with what I learned from the Drakart...

First Rule: NO OLD PARTS... eBay and the "TAKE OFFs" would harvest good, cheap, and NEW quality parts from Japanese ATVs'...

Second Rule: The best or nothing...

Third Rule: When the "nothing" part of the second rule applies, I MUST RESOLVE the problem with WHATEVER I had in my garage..


SO FAR..

1. Front Suspension from a 2014 YFZ 450. GOOD FIT. With stock CroMo tabs. ALLOT OF MEASUREMENTS, and I had to use a Camber/Caster GAGE.. But got -3 Camber on both Sides, and +5 Caster on both sides. (+-0.5)

2. Rack n Pinion steering. 14". with 3/4 u joint. Also bolted to stock tabs (AA Manufacturing!!).

3. The Ball Joints and rods, are "new" I had saved from years back, and are original FL350...

4. The Engine is a 4Cycle KLX450 "new". No reverse. But still should be good for 42HP+ with good torque, and with more than 20Kgs less, I have saved in suspension parts, etc. It should still have a decent power to weight ratio...

5. Brake Pedals and gear lever, are "Shifter Kart" Style. Actually the brake master cylinders where new, and I had them laying around. Same 13mm as original, and after much math, it seams perfect with the original front disk brakes from the YFZ, and the original FL350 rear caliper.

6. I like the GEARBOX Solution, the FL350 original, after much evaluation, I was able to reconfigure the original gears to get 3.3:1 to better match the 5 speed gearbox and the 10,500RPM of the new Engine. (And spare some weight..)

I wanted to post a "sneak peak" of what I am doing.... probably the worst of "FLankesteins" but I am having allot of fun....


Attachments:
File comment: FL350 with YFZ450 A ARMS.
FL350withYFZ450Aarms.jpg
FL350withYFZ450Aarms.jpg [ 35.14 KiB | Viewed 1628 times ]
File comment: Rack and Pinion.
2014-07-25 14.52.04.jpg
2014-07-25 14.52.04.jpg [ 48.48 KiB | Viewed 1628 times ]
File comment: Pedal Setup, "Shifter Kart Style"
2014-08-03 11.20.53.jpg
2014-08-03 11.20.53.jpg [ 58.97 KiB | Viewed 1628 times ]
File comment: Modified Gear Box. From 10:1 to 3.3:1 by removing 3 gears, and "FIXIN" one to the SHAFT. (Orange Mark)
2014-08-03 11.23.09.jpg
2014-08-03 11.23.09.jpg [ 51.57 KiB | Viewed 1628 times ]
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 Post subject: Re: FL350 "reloaded"
PostPosted: Tue Aug 26, 2014 2:18 pm 
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Joined: Tue Jan 17, 2012 3:19 am
Posts: 4400
Location: Hope, B.C Canada
WELL ....... you obviously have some mechanical ability and fab skills.
I do a lot of stuff myself (make my own liquid cooled heads and cylinders, intake manifolds) but it's not that I am cheap it's just that I like doing it.
Look forward to more from this post.


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 Post subject: Re: FL350 "reloaded"
PostPosted: Tue Aug 26, 2014 2:52 pm 
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Joined: Tue Jan 10, 2012 10:21 am
Posts: 2657
Location: NW Ohio / SE Michigan
canadian oddy wrote:
WELL ....... you obviously have some mechanical ability and fab skills.



....and spare time! lol


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 Post subject: Re: FL350 "reloaded"
PostPosted: Tue Aug 26, 2014 3:16 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22133
Location: Chicago
KOdy wrote:
Hi guys... here is my story... I used to have a Drakart. Bought the basic "sports" model from Alain, dropped the Kawasaki 750 V Engine, and swapped it for a Ninja 636.... It was SWEET... and then I sold it.... I miss the darn thing..

A few months back I was able to recover an FL350, I used to own, waaay back..

As I started to fix it again, I remembered the whole ordeal... and why I sold the thing in the first place, and forgot about it...

I decided to put some LIFE back into the FL350, with what I learned from the Drakart...

First Rule: NO OLD PARTS... eBay and the "TAKE OFFs" would harvest good, cheap, and NEW quality parts from Japanese ATVs'...

Second Rule: The best or nothing...

Third Rule: When the "nothing" part of the second rule applies, I MUST RESOLVE the problem with WHATEVER I had in my garage..


SO FAR..

1. Front Suspension from a 2014 YFZ 450. GOOD FIT. With stock CroMo tabs. ALLOT OF MEASUREMENTS, and I had to use a Camber/Caster GAGE.. But got -3 Camber on both Sides, and +5 Caster on both sides. (+-0.5)

2. Rack n Pinion steering. 14". with 3/4 u joint. Also bolted to stock tabs (AA Manufacturing!!).

3. The Ball Joints and rods, are "new" I had saved from years back, and are original FL350...

4. The Engine is a 4Cycle KLX450 "new". No reverse. But still should be good for 42HP+ with good torque, and with more than 20Kgs less, I have saved in suspension parts, etc. It should still have a decent power to weight ratio...

5. Brake Pedals and gear lever, are "Shifter Kart" Style. Actually the brake master cylinders where new, and I had them laying around. Same 13mm as original, and after much math, it seams perfect with the original front disk brakes from the YFZ, and the original FL350 rear caliper.

6. I like the GEARBOX Solution, the FL350 original, after much evaluation, I was able to reconfigure the original gears to get 3.3:1 to better match the 5 speed gearbox and the 10,500RPM of the new Engine. (And spare some weight..)

I wanted to post a "sneak peak" of what I am doing.... probably the worst of "FLankesteins" but I am having allot of fun....



Not sure what you did to change the ratio but if you had a second trans could you use the parts from the second trans and still keep reverse?


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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Aug 27, 2014 12:43 am 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
Not sure what you did to change the ratio but if you had a second trans could you use the parts from the second trans and still keep reverse?


Yes, reverse still works..

Here is what I did to change the RATIO..

Removed the 20 and 40 (Non accurate Teeth count, but close..) from MAIN INPUT SHAFT..

Then REMOVED the 16 from the second shaft, and keep the washers and bearings, just to make sure everything holds.

The 30 gear from the second Shaft MUST BE fixed, (I used a liner,KEY-Keyway, but I guess it could be welded and then put back on a lathe...) still TOO EARLY to tell if everything will hold.... Once TESTED I will give you more info..

Once tested, I will take pictures, and write up something more accurate.


Attachments:
2014-07-26 06.14.29.png
2014-07-26 06.14.29.png [ 444.56 KiB | Viewed 1572 times ]
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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Aug 27, 2014 3:05 pm 
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Joined: Tue Jan 10, 2012 10:21 am
Posts: 2657
Location: NW Ohio / SE Michigan
So essentially your just using the stock gearbox as a GEAR-TRAIN jack-shaft and final drive shaft as opposed to a chain and pair of sprockets.

I don't know if the input shaft bearings are gonna like 10,500 rpm for too long, particularly the AB needle bearings. But...you will generally only be spinning the input shaft when you've got the bike Engine in-gear, so you won't have that bearing killer perpetual input shaft spin idle -or- punishment from when you're parked and revv'ing her out. On the stock FL350's, its the "neutral cool guy Engine revv'ing" that kills the AB bearings from the lack of splash lube.

Got anymore pics of the front suspension in better light? Can barely make out the a-arms.


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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Aug 27, 2014 6:54 pm 
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Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3604
Location: CHICO,CA
KOdy wrote:
Not sure what you did to change the ratio but if you had a second trans could you use the parts from the second trans and still keep reverse?


Yes, reverse still works..

Here is what I did to change the RATIO..

Removed the 20 and 40 (Non accurate Teeth count, but close..) from MAIN INPUT SHAFT..

Then REMOVED the 16 from the second shaft, and keep the washers and bearings, just to make sure everything holds.

The 30 gear from the second Shaft MUST BE fixed, (I used a liner,KEY-Keyway, but I guess it could be welded and then put back on a lathe...) still TOO EARLY to tell if everything will hold.... Once TESTED I will give you more info..

Once tested, I will take pictures, and write up something more accurate.


if it docent last i have a bearing carrier with a sprocket and brake disc that was in a odyssey at one time


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 Post subject: Re: FL350 "reloaded"
PostPosted: Sat Aug 30, 2014 5:28 pm 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
With chain and sprocket ratio actual RPM with KLX450 @ 10500 Rpm should be close to 4000 at the input shaft.. actually lower than the oem..

Starting with a 13t to a 18t on the chain drive... I hope to test it soon..


Neutral would not move anything.. is in the Engine's gearbox.

Working this week end.. will take pictures with good light as soon as there is someting worth posting.... have fun.. Pura Vida..


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 Post subject: Re: FL350 "reloaded"
PostPosted: Sat Aug 30, 2014 5:59 pm 
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Joined: Sun Dec 24, 2006 5:58 pm
Posts: 1977
Location: near NJ rider
looks like a cool project Kody.

I like the Kart pedals, although most are going to cry about it.

Pretty slick modding the tranny.

Not sure about the front shock angle? looks a little off to me, have to see it at full bump.

Keep the pics coming.

Pura Vida..to you too. :-)


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 Post subject: Re: FL350 "reloaded"
PostPosted: Sun Aug 31, 2014 4:26 pm 
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Joined: Mon Sep 04, 2006 2:20 pm
Posts: 700
Location: Joliet, Illinois
The ody looks pretty good with your mods.......

The only thing you may want to consider on the foot pedals, is your feet slipping off if you get your shoes muddy, (or wet, depending what you are riding in)

Maybe figure out a way to make them non slip? Maybe modifying a set of foot pegs off of a dirt bike or quad (the kind with the searated(sp?) surface) Maybe slip them over the the existing pedals? Just a thought.

Again, looks pretty sharp


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 Post subject: Re: FL350 "reloaded"
PostPosted: Sun Aug 31, 2014 8:21 pm 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
Thanks guys... will follow advice on the pedals.. Me and the kids used to race Karts.. so the pedal setup feels right.. I am already working on the Engine mounts and rear suspension setup.


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 Post subject: Re: FL350 "reloaded"
PostPosted: Sun Aug 31, 2014 8:34 pm 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
Attachment:
20140830_181008.jpg
20140830_181008.jpg [ 59.26 KiB | Viewed 1483 times ]


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 Post subject: Re: FL350 "reloaded"
PostPosted: Fri Sep 12, 2014 5:49 pm 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
Gearbox working fine @ 3.3 ratio.
Some more Pics.


Attachments:
2014-09-10 22.39.48.jpg
2014-09-10 22.39.48.jpg [ 40.41 KiB | Viewed 1450 times ]
File comment: Liner Welded, some cutting on the lathe to refinish (no friction, since there is no soprocket next to this one). Keyway and key stop it from spining, now it is fixed to 2nd shaft, powering 3rd shaft.
2014-09-10 21.15.20.jpg
2014-09-10 21.15.20.jpg [ 42.4 KiB | Viewed 1450 times ]
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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Oct 28, 2015 2:37 am 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
Advancing.. step by step


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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Oct 28, 2015 2:41 am 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
Klx450


Attachments:
20151026_055551.jpg
20151026_055551.jpg [ 54.02 KiB | Viewed 1207 times ]
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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Oct 28, 2015 2:56 am 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
Yes..


Attachments:
20151026_055618.jpg
20151026_055618.jpg [ 61.55 KiB | Viewed 1205 times ]
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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Oct 28, 2015 1:00 pm 
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Joined: Sun Dec 24, 2006 5:58 pm
Posts: 1977
Location: near NJ rider
Looks good.

Good to see your still on it.


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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Oct 28, 2015 1:51 pm 
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Joined: Tue Jan 17, 2012 3:19 am
Posts: 4400
Location: Hope, B.C Canada
Very nice work.
I thought this project just died as we didn't here anything for a long time.


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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Oct 28, 2015 9:46 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3177
Location: Oklahoma City, OK
Now that's cool, hope the 4 stroke works for you, cant wait for ride report!


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 Post subject: Re: FL350 "reloaded"
PostPosted: Wed Oct 28, 2015 11:59 pm 
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Joined: Tue Jan 17, 2012 3:19 am
Posts: 4400
Location: Hope, B.C Canada
What is that rack and pinion steering out of ??


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 Post subject: Re: FL350 "reloaded"
PostPosted: Thu Oct 29, 2015 1:58 am 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
http://www.amazon.com/Latest-Rage-Rack- ... B00CMC3INU

This is the Rack


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 Post subject: Re: FL350 "reloaded"
PostPosted: Thu Oct 29, 2015 2:37 am 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
The 450 should perform in balance with the chassis and brakes...

Some people use 450cc engines for racing..

https://youtu.be/znngjNHYOfc

The 450 and original tranny seem to get along very well.. motor (( Internal Combustion Engine ? )) mount is version 3.0.. discarted other options.. ended up with a very simple one using original mounts with extension brackets in rear and new cro-mo tabs up front.

Still quite a few issues to solve... but it sure is a great project to relax and drop the electronics for a while...

Working on a gas tank solution, a replacement for my rear brake caliper.. and.. the wiring harness...

Best regards to all at this forum..


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 Post subject: Re: FL350 "reloaded"
PostPosted: Thu Oct 29, 2015 6:22 am 
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Joined: Sun Jan 10, 2010 9:14 pm
Posts: 1446
Location: Ma
Regarding the foot pedals, I found the that I needed my pedals to be smooth to allow my feet to glide on them... But I needed heel supports to keep my feet in place on uneven terrain it also helps keep the buttocks in the seat. It's amazing how much I was pushing against the foot tub prior to installing the foot pedals.
Looks good, keep us posted.


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 Post subject: Re: FL350 "reloaded"
PostPosted: Thu Oct 29, 2015 2:28 pm 
Offline

Joined: Tue Jan 17, 2012 3:19 am
Posts: 4400
Location: Hope, B.C Canada
KOdy wrote:
The 450 should perform in balance with the chassis and brakes...

Some people use 450cc engines for racing..

https://youtu.be/znngjNHYOfc

The 450 and original tranny seem to get along very well.. motor (( Internal Combustion Engine ? )) (( Internal Combustion Engine ? )) mount is version 3.0.. discarted other options.. ended up with a very simple one using original mounts with extension brackets in rear and new cro-mo tabs up front.

Still quite a few issues to solve... but it sure is a great project to relax and drop the electronics for a while...

Working on a gas tank solution, a replacement for my rear brake caliper.. and.. the wiring harness...

Best regards to all at this forum..


I saw a pilot in that video. Was that you ??


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 Post subject: Re: FL350 "reloaded"
PostPosted: Mon Nov 02, 2015 11:19 am 
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Joined: Sun Jun 15, 2014 1:25 am
Posts: 40
Location: Costa Rica
No. This is just a random video I found.. searching for what type of performance I could expect from the 450cc MX/ATV Engine
.


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