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BS's FL537 rotax conversion

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DMoneyAllstar

Post subject: Re: BS's FL537 rotax conversion

Posted: Thu Nov 14, 2013 1:52 pm

Joined: Tue Jan 10, 2012 10:21 am
Posts: 2681
Location: NW Ohio / SE Michigan

hoser wrote:

DMoneyAllstar wrote:

B S wrote:

Yo D$* got a pic of that air filter set up?

I'll snap a pic of the airbox I've got tonight. Its nice and small, has the typical clamshell design, and has an inlet and outlet port (much larger than my d/d carb). So I can plumb a big clunky K&N conical pre-filter to catch mud/etc and keep the primary filter dry & cozy and not make too many turns and bends.

Its for a Chrysler 2.5L automobile Engine that redlines at ~6500rpm, thus per the SAE J726 air flow formula, the Engine is flowing max ~201 CFM. My 2-stroke 470cc Rotax at 8500rpm is only flowing 97 CFM. Which means there's PLENTY of filter and half the face velocity. This really efficient filter will flow fantastic and will have plenty of life (dirt capacity) for a buggy that doesn't turn anywhere close to the miles of the intended application. Yes, the conditions are likely 2x as harsh but the filter will still go above and beyond its call of duty on the buggy. The media technology & performance is far superior to what a K&N-type filter will offer.

A 540cc 2-stroke at 8500rpm will move roughly 113 CFM of air.

Yes pics please, its refreshing to see someone thinking about filtration, air flow, velocity, CFM etc.

Its amazing how some simple math can prevent some dumb mistakes and cost. Like here at work, everything gets run through Pro/Mechanica's FEA program before we spend a dime on materials or prototype tools. Designing stuff via the "cowboy method" just isn't feasible.

hoser wrote:

I even have a dual filter setup on my home HVAC system, prefilter then 30 or so feet of duct away another filter right at the furnace to catch what the first filter missed :-)

Ha, same here. I've got a standard "bug catcher" filter on my HVAC and then a Honeywell HEPA filter that's about 6" thick there after. I even flow-tested it with the ol' tissue-paper-strip-taped-to-the-register-test to make sure it wasn't killing flow. Helps that the furnace was spec'd out to include the HEPA. The good filter really makes a difference, especially in the winter time when the windows are never open -- my picture frames and furniture doesn't have much dust build-up.

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B S

Post subject: Re: BS's FL537 rotax conversion

Posted: Sun Nov 17, 2013 6:40 am

Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA

Well I found a set of brake lines that fit the LT front end on my odyssey
There off of a 05-07 suzuki king quad 700 4x4 front brake lines

They fit perfectly for the price paid $10.99 shipped
And also found out that the shorter hose from the front lines from the 700 quad will fit the rear caliper hose it's abought 1/2" longer than the factory one will post a pic in tech stuff

So I got all the brakes installed and bleeded today
Got to setup the bump stops tomarrow so I can test ride it
battery box mounted in the factory location had to re weld a piece back on there from what I cut off preveoicly
Regulator/rectifier mount made
Tach is temp mounted with hose clamps :-)

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shoubadaba

Post subject: Re: BS's FL537 rotax conversion

Posted: Sun Nov 17, 2013 6:23 pm

Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca

its getting there. what else do you have planned for the ody?

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hoser

Post subject: Re: BS's FL537 rotax conversion

Posted: Sun Nov 17, 2013 6:33 pm

Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22516
Location: Chicago

Looking really good.

When you fabricate your brackets look at how you can make them lighter weight like your regulator bracket you can drill a bunch of holes in it and not affect the strength any, also put a bit radius on all the edges I mention this because I have scars from sharp edges and it sucks lol

Your going to love the power of this thing :-)

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nickRNR

Post subject: Re: BS's FL537 rotax conversion

Posted: Mon Nov 18, 2013 12:24 am

Joined: Thu Oct 30, 2008 8:22 pm
Posts: 2641
Location: Rancho Cucamonga, Ca

hoser wrote:

Your going to love the power of this thing :-)

Oh he does LOL, he sent me a voxer after driving it and it sounded like he spooged in his panties!

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shoubadaba

Post subject: Re: BS's FL537 rotax conversion

Posted: Mon Nov 18, 2013 1:00 am

Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca

lol giddy as school girl for sure!

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B S

Post subject: Re: BS's FL537 rotax conversion

Posted: Mon Nov 18, 2013 5:36 am

Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA

nickRNR wrote:

hoser wrote:

Your going to love the power of this thing :-)

Oh he does LOL, he sent me a voxer after driving it and it sounded like he spooged in his panties!

lol
i diddnt spoog in my paints :-)

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B S

Post subject: Re: BS's FL537 rotax conversion

Posted: Mon Nov 18, 2013 7:25 am

Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA

As you can see by the previous comments it was a good test ride

Found out I have a hole in my tank :shock:

Fixed it with some duck tape for now :-)

will weld later

Any one got a manual of how to jet these super bn carbs pretty sure mine is a super bn because it has a square fuel pump
The bottom end is way too fat takes a while to clean its self out when you hit the throttle
I'm running 32/1 mix but thinking about running 40/1 the exhaust is pretty oily looking already
what do u run for mix in the rotax hoser?

Looking like I might have to get a longer belt for it the drive clutch isn't shifting out all the way but the driven looks like it is

Still got lots to do t call it finished

Have To order all the bolts and nuts so I can finish the front
currently the front has 3/8 bolts in it for the a arms

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hoser

Post subject: Re: BS's FL537 rotax conversion

Posted: Mon Nov 18, 2013 8:49 am

Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22516
Location: Chicago

I run mine at 28:1 yours looks oily because the bottom end is too fat lean it out some, you tried adjusting the low speed screw?

Warm the Engine up good then let it idle for about 1 minute turn the screw just a little then allow at least 30 seconds without touching the throttle for it to respond.

Get the jetting right at it will burn the oil :-)

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DMoneyAllstar

Post subject: Re: BS's FL537 rotax conversion

Posted: Mon Nov 18, 2013 9:40 am

Joined: Tue Jan 10, 2012 10:21 am
Posts: 2681
Location: NW Ohio / SE Michigan

Lookin' good! Nice stance.

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nitrosport_5

Post subject: Re: BS's FL537 rotax conversion

Posted: Mon Nov 18, 2013 12:29 pm

Joined: Tue Aug 03, 2010 12:02 am
Posts: 2147
Location: St. John, Washington

B S wrote:

Looking like I might have to get a longer belt for it the drive clutch isn't shifting out all the way but the driven looks like it is

you won't get the drive clutch to shift all the way with a stock width belt. Chad and I were just talking about this, the tea clutch is limited on how far it will pinch closed. would take some slight machining to get it to work properly

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B S

Post subject: Re: BS's FL537 rotax conversion

Posted: Tue Nov 19, 2013 12:10 am

Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA

nitrosport_5 wrote:

B S wrote:

Looking like I might have to get a longer belt for it the drive clutch isn't shifting out all the way but the driven looks like it is

Driven is maxed out
And it's leaving Some black on the face of the drive still has a inch to go

Looks like I'll be ordering a longer belt

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hoser

Post subject: Re: BS's FL537 rotax conversion

Posted: Tue Nov 19, 2013 9:54 am

Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22516
Location: Chicago

B S wrote:

nitrosport_5 wrote:

B S wrote:

Looking like I might have to get a longer belt for it the drive clutch isn't shifting out all the way but the driven looks like it is

Driven is maxed out
And it's leaving Some black on the face of the drive still has a inch to go

Looks like I'll be ordering a longer belt

Is it the length or width that is the issue?

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DMoneyAllstar

Post subject: Re: BS's FL537 rotax conversion

Posted: Tue Nov 19, 2013 11:26 am

Joined: Tue Jan 10, 2012 10:21 am
Posts: 2681
Location: NW Ohio / SE Michigan

Is anyone running a Rotax without the TRA clutch, with like a 94c, 102c, Powerbloc, etc?

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nitrosport_5

Post subject: Re: BS's FL537 rotax conversion

Posted: Tue Nov 19, 2013 3:14 pm

Joined: Tue Aug 03, 2010 12:02 am
Posts: 2147
Location: St. John, Washington

DMoneyAllstar wrote:

Is anyone running a Rotax without the TRA clutch, with like a 94c, 102c, Powerbloc, etc?

I believe hoser is on his 440. want to say a power block. only downside I see is no electric start

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DMoneyAllstar

Post subject: Re: BS's FL537 rotax conversion

Posted: Tue Nov 19, 2013 5:19 pm

Joined: Tue Jan 10, 2012 10:21 am
Posts: 2681
Location: NW Ohio / SE Michigan

nitrosport_5 wrote:

DMoneyAllstar wrote:

Is anyone running a Rotax without the TRA clutch, with like a 94c, 102c, Powerbloc, etc?

I believe hoser is on his 440. want to say a power block. only downside I see is no electric start

Ohhhh yaaaaa, forgot about the ol' e-start ring gear. My bad.

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fully

Post subject: Re: BS's FL537 rotax conversion

Posted: Tue Nov 19, 2013 7:47 pm

Joined: Mon Jul 19, 2010 3:20 pm
Posts: 1718
Location: saskatoon, sk, canada

i still need brake lines for the fl450r. how did you route those lines. how did you attach to the master cylinder

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B S

Post subject: Re: BS's FL537 rotax conversion

Posted: Tue Nov 19, 2013 11:55 pm

Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA

fully wrote:

i still need brake lines for the fl450r. how did you route those lines. how did you attach to the master cylinder

Zip tied for now :-)

Running a pilot wheel But it has the same ends as the odyssey master.

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B S

Post subject: Re: BS's FL537 rotax conversion

Posted: Wed Nov 20, 2013 12:00 am

Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA

Got the tank fixed last night
Drilled the hole out to clean it out
Made a little pop and sprayed me with water
Welded like shit had to drain all the water out then weld it with the cap off lit it with a torch to burn all the fums out made a woosh sound

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B S

Post subject: Re: BS's FL537 rotax conversion

Posted: Wed Nov 20, 2013 12:02 am

Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA

hoser wrote:

is it the length or width that is the issue?

Length

Thanks Ace for the link

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shoubadaba

Post subject: Re: BS's FL537 rotax conversion

Posted: Wed Nov 20, 2013 12:07 am

Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca

LOL that's what she said

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fully

Post subject: Re: BS's FL537 rotax conversion

Posted: Wed Nov 20, 2013 9:28 am

Joined: Mon Jul 19, 2010 3:20 pm
Posts: 1718
Location: saskatoon, sk, canada

those brake lines fit nice..i looked at some think i will order them instead of doing the steel braided.. all the ones i looked at say it cost $30 to ship. that sounds like a lot to ship a small box

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B S

Post subject: Re: BS's FL537 rotax conversion

Posted: Wed Nov 20, 2013 5:38 pm

Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA

fully wrote:

those brake lines fit nice..i looked at some think i will order them instead of doing the steel braided.. all the ones i looked at say it cost $30 to ship. that sounds like a lot to ship a small box

They fit nice got them for $10.99 shipped :-)

saved me some $$$
Also a added bonus the short line from that will fit on the rear caliper it's 1/2" longer

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B S

Post subject: Re: BS's FL537 rotax conversion

Posted: Thu Nov 21, 2013 12:36 am

Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA

Will this Engine run better with dual 38mm carbs ?

Been thinking of picking up a dual 38 carbs intake

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shoubadaba

Post subject: Re: BS's FL537 rotax conversion

Posted: Thu Nov 21, 2013 12:46 am

Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca

Oh yeah it will rip!

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