The Diesel Project

[franque]

Originally Posted by cheesy

The sprocket cover with the clutch actuator came today, so that’s something. I also drilled out the rivets that hold the clutch basket, driven gear, and backing plate together. I have a think on how to make it work.

Thinking about it, you could run it how the motorcycle was (likely) set up before, with the clutch running directly on the transmission, instead of the crankcase, with there being no clutch on the engine itself or the jackshaft. Was the clutch on the diesel originally a centrifugal clutch?

You might be able to take the original gear off of the clutch basket, and have a sprocket riveted on, with that connecting via chain to the jackshaft, which would probably also be connected to the chain via chain.

[cheesy]

Originally Posted by franque

Thinking about it, you could run it how the motorcycle was (likely) set up before, with the clutch running directly on the transmission, instead of the crankcase, with there being no clutch on the engine itself or the jackshaft. Was the clutch on the diesel originally a centrifugal clutch?

You might be able to take the original gear off of the clutch basket, and have a sprocket riveted on, with that connecting via chain to the jackshaft, which would probably also be connected to the chain via chain.

Ding ding ding. Except not using a jackshaft. Yet.

The machine the engine came off of was belted directly to a grind stone. Everyone loved the power but hated the weight of the engine. The diesel sucks when in order to tilt the angle of the stone, you need to tilt the angle of the engine.

I need to retain the body of the driven clutch gear because of the springs and bearings. I’m going to have my buddy machine off the gear teeth. Then scrounge the perfect sprocket and have that bored for a press fit on the gear body.

[franque]

You might want to make a housing that the sprockets can be bolted to, that's tapered and has a keyway to keep it from slipping and moving under load, possibly bolted down like the flywheel on a CB/CG motor, or a Harley primary sprocket.

At the very least, you should add a keyway to retain it, and possibly use the bearing retaining Locktite.

[cheesy]

Once pressed on, with 6xx Loc-tite, I intend to drill three holes 120* apart at the joint and press pins in, also with 6xx.

[franque]

Ah. That should work just fine.

[lilgman]

I check this post pretty much every day for an update. I'm assuming life is happening, but I can't wait to see a real, live diesel motorcycle!

[cheesy]

I hope to get something done this weekend even if it’s just marking cuts with a tape measure and paint pen.

I’ve seen an awful lot of MN, ND, and WI this week. Translates into 2.5 hrs work with 2500 miles of driving. Last week was CO. Week before was upstate NY. I have sort of an agreement with the missus that if I spend five days away from home, I won’t spend the weekend in the garage.

[cheesy]

Got a little bit done today. All the handlebar controls are mounted. Need to figure out the wiring yet.


Got the engine off the bench without busting a nut. It weighs A LOT less without the muffler and air filter.


I sent this pic to Inky Tim and said I would need his fabbing expertise to help in getting this 10 pounds of crap into a five pound bag. I don’t want to stretch the frame but I think we can alter the cradle to make it work. The kid is already coming up with ideas.

[cheesy]

Did some butchering yesterday and also hung the front end to check clearance.


Using the angle finder, the original angle of the down tubes is 68*. By moving the down tubes to 90*, I gain several inches without having to stretch the frame. It looks like I will need to elevate the engine a few inches so the starter clears the trans but there is plenty of room for that. I ordered two 24” pieces of 1” steel tube to replace the cut down tubes. I will let Tim work his magic with the bends, then I will weld them into place.

Odd thing about that front end. Definitely a Suzuki fork and wheel, but all the specs I read for the GS550L call for a 16” wheel, this one is a 19”. I’m not too sure it’s an air fork, either.

[franque]

Does it have a Schrader valve on the forks?

[cheesy]

Not that I can see.

[franque]

Almost definitely not air forks then, unless they're aftermarket, which I really doubt.

[cheesy]

I’m thinking older Suzuki but not sure until I tear into it.

[cheesy]

The rear brake pedal came today and I had an hour or so to kill this afternoon, so...

[cheesy]

Tim stopped by today to have a gander at the frame. Took him less than a minute to figure out what to do and how to do it. Should have his idea in my hands by the end of the month.