Jawa / VVM [dieselmaster]

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andrewaust
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Re: Jawa / yanmar clone

Post by andrewaust » Mon Jun 13, 2011 8:23 am

Good job vincentyeager, haven't contributed to the thread, just enjoying the read, including other members input.


A ;)

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Re: Jawa / yanmar clone

Post by Curtis in Texas » Mon Jun 13, 2011 6:51 pm

You guys are killing me.
Here I sit with more projects than I can get to, and you put this idea in my head to cut up an old engine and Frankenstien the transmission out of it. :D

I have about 1/2 dozen Honda 125 cc engines setting on a back shelf, so I could easily afford to screw up a few to perfect this for myself...
If I could find the time!!!!!!
Keep up the good work......

Can't wait to see a video of it running down the street.

C.D.
Last edited by Curtis in Texas on Sat Jun 18, 2011 4:22 pm, edited 1 time in total.
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Re: Jawa / yanmar clone

Post by balboa_71 » Tue Jun 14, 2011 2:00 am

Curtis,
I think the only tranny's good for a transplant are 2 stroke units due to the fact that they are sealed from the engines crankcase. I'd like to hear from others on their opinion regarding this. We have so many 4 stroke engines here in the country, but little to no 2 strokes. Yamaha twins are the most popular vintage 2 strokes left, but shame to cut up. Some 4 bangers use engine oil pressure to lubricate the tranny like the old Yamaha XT 500's....

Cris
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Re: Jawa / yanmar clone

Post by Curtis in Texas » Tue Jun 14, 2011 10:00 pm

balboa_71 wrote:Curtis,
I think the only tranny's good for a transplant are 2 stroke units due to the fact that they are sealed from the engines crankcase. I'd like to hear from others on their opinion regarding this. We have so many 4 stroke engines here in the country, but little to no 2 strokes. Yamaha twins are the most popular vintage 2 strokes left, but shame to cut up. Some 4 bangers use engine oil pressure to lubricate the tranny like the old Yamaha XT 500's....

Cris
Thanks Cris. IIt has been so long since I worked on two stroke bikes that fact completly slipped my mind. know where some 2 stroke bikes are setting rigt now.

See you Friday!
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Re: Jawa / yanmar clone

Post by vincentyeager » Wed Jun 15, 2011 4:06 pm

Cutting up an XT engine, that be lots more of a shame than any yamaha two-stroke..

I'd like to emphasize that its not just me, 'vincentyeager', Jeroen (boutje) is putting in alot of effort in it as well.

time for some more pics, since we've made some progress;


upper strut, this will add stiffness
12.jpg
13.jpg
front left mount, its welded all down the back :wink:
14.jpg
and here you can see how the aluminum part was machined;
http://www.youtube.com/watch?v=MgwiNoOPv0Y

later! :)

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Re: Jawa / yanmar clone

Post by arnaud » Sat Jun 18, 2011 12:45 pm

Hi, i'm inpressed that it fits all in the frame, and wonder what you will do with the flywheel, since the engine needs the weight of it for tickover and balancing out the blows, and wonder if the gearbox can cope with the diesel power.
Would like to see the result for real! maybe Hamm this year or sooner?

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Re: Jawa / yanmar clone

Post by balboa_71 » Sat Jun 18, 2011 2:56 pm

Very creative method of attaching the cylinder head to frame, should stiffen the bike up a good amount....you're not going to flex a clone engine. What gearbox are you using?

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Re: Jawa / yanmar clone

Post by Sphere » Sat Jun 18, 2011 3:14 pm

The Jawa one.
'92 Enfield + Hatz 1B40: street legal, weld up stainless exhaust, check engine rpm and change final drive sprocket.

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Re: Jawa / yanmar clone

Post by coachgeo » Sat Jun 18, 2011 10:01 pm

arnaud wrote:Hi, i'm inpressed that it fits all in the frame, and wonder what you will do with the flywheel, since the engine needs the weight of it for tickover and balancing out the blows, and wonder if the gearbox can cope with the diesel power.
Would like to see the result for real! maybe Hamm this year or sooner?
hmm.... good point. completely missed that he no longer has a flywheel. hmmmm.....

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Re: Jawa / yanmar clone

Post by vincentyeager » Sun Jun 19, 2011 8:45 am

the flywheel will be around 50% lighter then the original one. This is not abnormal to do, it will make the bike more souple and reactive.

More important, the exhaust is nearing completion;
15.jpg

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Re: Jawa / yanmar clone

Post by Dougy » Sun Jun 19, 2011 10:43 am

Your flying now mate, loving this build, the flywheel may be lighter but you've also added more flywheel weight in the transmission chain, clutch basket & plates ect so I think it should all balance out nicely, looks like a top quality job on that exhaust too ! :) MORE MORE :)
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Re: Jawa / yanmar clone

Post by arnaud » Mon Jun 20, 2011 9:28 am

I'm getting more curious, come to my house show the bike as soon it is ready? (you need to runi-in the engine.. :lol: )

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Re: Jawa / yanmar clone

Post by vincentyeager » Tue Jul 05, 2011 8:39 pm

powerpack, quick 'jawa' shifting :wink:
its not as heavy as it looks.
16.JPG
and with the cover;
17.JPG
plan is to sandblast&''glasspearl'' (?) all the custom aluminium work

:)

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Re: Jawa / yanmar clone

Post by vincentyeager » Wed Jul 13, 2011 9:08 pm

hi-flow filter and inlet manifold
18.jpg
along with the exhaust, its all part of vvm diesel stage one.


jiffy stand situated on the unconventional right side of the bike
19.jpg
or should we say of the ''dikke brommer'' (dutch for big/fat moped).

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Re: Jawa / yanmar clone

Post by vincentyeager » Fri Jul 22, 2011 8:14 pm

Flywheel (with v-groove situated at the front) is ready,
Jeroen busted his behind on this piece!
20.jpg
and took the first step towards improved aerodynamics
21.jpg

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Re: Jawa / yanmar clone

Post by Dougy » Sat Jul 23, 2011 10:54 am

Looks like your nearly ready for the maiden voyage mate :) your right about the flywheel to, it looks like a lot of hours have gone into it.
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Re: Jawa / yanmar clone

Post by vincentyeager » Thu Jul 28, 2011 8:20 pm

look what Jeroen's itching hands produced this time
22.JPG
it will include a 'kill' position as well
:D

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Re: Jawa / yanmar clone

Post by Dougy » Sat Jul 30, 2011 12:41 am

Bloody hell mate it just gets better an better, when your finished with him send Jeroen over here will ya, does he eat much :?: :lol: If they had a build of the year prize I'd vote for your Jawa no contest ! :)
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Re: Jawa / yanmar clone

Post by Crazymanneil » Sat Jul 30, 2011 9:31 pm

Just found this thread. Really nice build! Should be a nice bike to enjoy when its finished, hats off to you.

Neil
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Re: Jawa / yanmar clone

Post by old clunker » Sat Aug 27, 2011 10:30 pm

Nice bit of engineering by both of you, and good to see old two strokes getting a new lease of life. There must be plenty around still, that are ideal for a diesel conversion. It looks like the Jawa bike will be good to ride.
My first bike was a Yamaha 2 stroke, and was quite fun to tune up the engine and exhaust.

I'm sure that a 1970's Suzuki T500 or GT500 with a blown or dying engine, would also be an ideal candidate for a diesel conversion. Well built, classic looks, and one of the best large capacity (500cc) 2 strokes for its day for reliability and build quality. Suzuki in those days almost over-engineered their bikes to get a good reputation for quality. I think that there are a few still around for about £1000 or maybe less, and I've seen an occasional one still 'rattling' away on the roads fairly recently.

Good luck with the finishing off, and the first test ride of the Jawa!
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Re: Jawa / yanmar clone

Post by Mouse » Sat Aug 27, 2011 11:39 pm

Cant wait to see this one going.

PS does anyone else find that statue spooky? :twisted:
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Re: Jawa / yanmar clone

Post by coachgeo » Sun Aug 28, 2011 1:59 am

Mouse wrote:Cant wait to see this one going.

PS does anyone else find that statue spooky? :twisted:
Plus one on both counts

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Re: Jawa / yanmar clone

Post by vincentyeager » Sun Aug 28, 2011 7:10 am

going....around europe next year and maybe even to the jawa factories? :P

Here a short movie of how the diesel pump is operated:

http://www.youtube.com/watch?v=5Fb-gypB ... ideo_title

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Re: Jawa / yanmar clone

Post by Stuart » Sun Aug 28, 2011 7:32 pm

Yes, the statue thing IS a bit spooky 8)

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Re: Jawa / yanmar clone

Post by boutje » Mon Aug 29, 2011 3:03 pm

..
Last edited by boutje on Fri Dec 05, 2014 10:47 am, edited 1 time in total.

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Re: Jawa / yanmar clone

Post by snoopy » Sun Sep 11, 2011 8:43 pm

You will probably have major issues from lightening the flywheel, the weight is needed to keep it going at lower rpm and also for kickstarting (on the Enfield), without it it will not have the momentum to keep going past the decompressed cycle.

Nice engineering btw on the regulator
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Re: Jawa / yanmar clone

Post by vincentyeager » Thu Sep 15, 2011 11:36 am

The weight hasnt really changed, only the diameter.
I've read somewhere on this board i believe, that these yanclones need an idle rpm of ~1200 to keep it from hurting itself.
We'll see how it goes.

In the meanwhile the welds on the gearbox are grinded flat, and afterwards having it in my kitchens oven at 300degC for 6 hours.
We have a nice overal hardness of the aluminium now; http://www.youtube.com/watch?v=Oq_Zc288gT4
and please, dont use household oven gloves like i did *ouch* :oops:
rather use a big set of plyers like the real mcCoy!

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Re: Jawa / yanmar clone

Post by Curtis in Texas » Thu Sep 15, 2011 1:16 pm

vincentyeager wrote:The weight hasnt really changed, only the diameter.
I've read somewhere on this board i believe, that these yanclones need an idle rpm of ~1200 to keep it from hurting itself.
We'll see how it goes.
That's kinda the way I was thinking about the flywheel weight on this engine. If you add a transmission and clutch and they spin with the crankshaft then you still get the flywheel effect, only it's remote. That's going to be factored into my build since it will be using a harley Clutch and transmissin. And we all know how lightweight Harley parts are..... :o
vincentyeager wrote:In the meanwhile the welds on the gearbox are grinded flat, and afterwards having it in my kitchens oven at 300degC for 6 hours.

We have a nice overal hardness of the aluminium now; http://www.youtube.com/watch?v=Oq_Zc288gT4
and please, dont use household oven gloves like i did *ouch* :oops:
rather use a big set of plyers like the real mcCoy!
Love it. My first wife used to hate it when I used her Oven to heat up my race car parts. HA! :D
Probably why she's my EX. She wanted a normal rich guy who didn't build junk in the house I guess!
Too bad the guy she divorced me to marry had less money than I did. But he told good lies.

When it came to my second wife, I made sure she knew, before we got married, that no appliances were sacred. Chuckle :lol:

Good tip about the gloves.
Curtis in TX
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Re: Jawa / yanmar clone

Post by vincentyeager » Thu Sep 15, 2011 5:59 pm

Curtis in Texas wrote:
vincentyeager wrote:
Love it. My first wife used to hate it when I used her Oven to heat up my race car parts. HA! :D
Probably why she's my EX. She wanted a normal rich guy who didn't build junk in the house I guess!
Too bad the guy she divorced me to marry had less money than I did. But he told good lies.

When it came to my second wife, I made sure she knew, before we got married, that no appliances were sacred. Chuckle :lol:

Good tip about the gloves.
Curtis in TX
First thing Jeroen asked me before we started to build if i had any social obligations;
I said no, because i had just ditched my (ex-)girl. i probably couldnt have done all of this with her :lol:

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Re: Jawa / yanmar clone

Post by Dougy » Thu Sep 15, 2011 8:18 pm

I've built most of my bikes in the living room with the HELP of my Mrs :D I cant imagine having to ask permission to build or having to deal with a nag ! The only thing differant I would have done is chuck in a leg of lamb half way through hardening it :lol:
Another good vid, but Hurry up mate I'm bursting to see it run 8)
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