FL250 With Yamaha 540 Sled Build

[fl250540]

Just moved to Hawaii and was in need of a new project, I found this Fl250 on CL. It had a cbr1000 on it that i didn't buy with the kart. Found a SRV540 Snow mobile engine on CL as well that the guy was going to use for an airplane, probably the only snow mobile engine on the island. I wont have a house for about a month, but wanted to show you guys what i plan to build in the near future. Any advise is appreciated.

 

[Doc Sprocket]

My advice is to talk to Bighead. When he cuts himself, he bleeds Odyssey.

 

[frankysfree]

Ill second that. In fact over on my odyssey build thread he linked a bunch of pics and videos and he has a snowmobile engined ody.

 

[fl250540]

One step ahead of ya, thanks though, hes been a bighelp so far.

 

[j.concepcion54321]

hey do you have the clutch system for that engine? if not you better start looking into one

 

[fl250540]

Yes I bought the stock sled primary clutch and belt off ebay. I need to buy shocks for the rear suspension. (http://www.ebay.com/itm/230699143581?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649) heres some shocks i am thinking of getting.

 

[fl250540]

I plan on widening the stock rear end to add room for the engine and improve handeling.

 

[bighead]

Take a better pic of that gear box and axle area? Need to see what going on there. (is it laying on the ground?) Also try to use that exhust if you can. The run so much better and all day with stock pipe. There ugly but you can make them look cool if your lucky. I was able to run mine right up the side. You got a good sled engine. Single carb air cooled works well on the Ody's. Does it have electric start? Also use that oil tank in your build. I do not like just using just mixed gas unless your a carb wiz. Run it as staock as you can. And get the engine as low as you can.


Missed this thread sorry.

 

[bighead]

If you get that axle.

http://www.youtube.com/watch?v=hHYGrJC_fa4

 

[bighead]

http://www.youtube.com/watch?v=j-RXoEyzYjI

http://www.youtube.com/watch?v=dhYpZcympiQ

http://www.youtube.com/watch?v=M6iiN3sL8xA

 

[bighead]

Yes I bought the stock sled primary clutch and belt off ebay. I need to buy shocks for the rear suspension. (http://www.ebay.com/itm/230699143581?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649) heres some shocks i am thinking of getting.

If you using rear suspension I would fix that back section and start over. They added the whole rear section in anyway. (bumper part) The back bar on your frame is not original. And the welds look really bad from the pics. POR15 would be perfect paint for your Ody.


Follow Frankies suspension ideas might work for you as well. Also make a list of the parts you need I may have them. Do you have the missing level from the steering wheel? Caliper?

 

[fl250540]

Take a better pic of that gear box and axle area? Need to see what going on there. (is it laying on the ground?) Also try to use that exhust if you can. The run so much better and all day with stock pipe. There ugly but you can make them look cool if your lucky. I was able to run mine right up the side. You got a good sled engine. Single carb air cooled works well on the Ody's. Does it have electric start? Also use that oil tank in your build. I do not like just using just mixed gas unless your a carb wiz. Run it as staock as you can. And get the engine as low as you can.


Missed this thread sorry.

The karts at a friends house untille we get moved into ours on the 27th. im living in a hotel till then, anxiouse to get to work on this beast and make some progress. have a great place to ride here in hi, with 400 acres of trails. checked that out yesterday. i plan to use everything that i have from the sled, gonna run it on pre mix to check the oil pump on the first run. then go from there and use it if its pumping good. i gotta get a fuel tank. It does have electric start with a small battery and yamaha ignition, i like that allot.

The rear axle will not bolt up at the moment due to the reinforcing the guy did. i think this is where he stopped. im gonna rebuild the entire rear end, i agree his welds are ugly, but like you said por 15 does wonders and a grinder with wire brush will clean allot of that up. Wanna do the rear suspension simillar to Frankies. Im worndering how the ride will be, i might go with bigger tires on the rear for more ground clearance, and this making it possible for more travel in suspension without bottoming out.

? with the front shocks disconnected from the j arm does the suspension hang? i was thinking about getting some 11" shocks to replace the front. looking to gain travel

? does the sled throttle connection need to be a push or pull cable?

? Are rear reduction boxs different between the years? Ive read the older ones where weak.

I do not have the other lever, im still not 100% on wether i wanna use the levers or get a pedal assy for the throttle and build a pedal from the quad mater cylinder and lever i bought for the 400ex disks and hubs.

Thanks for the help

Heres some pics of the gearbox i plan to use, sled belt, and two different clutchs for the 540. will probably use the yamaha one at first.

 

[frankysfree]

I posted pics on my build thread of how I did the bushings for the rear suspension.

If I remember right the only difference in the early and late gear boxes was the chain. Seems I heard you just put the late model chain in the early box to beef it up. If I'm wrong I'm sure bighead will correct me.

 

[fl250540]

i got the entire gearbox from ebay, not sure what year its from, gonna have to make a trip to the other side of the island to get the chain thats for the buggy, thought it went with the cbr engine when i bought it.

 

[bighead]

The karts at a friends house untille we get moved into ours on the 27th. im living in a hotel till then, anxiouse to get to work on this beast and make some progress. have a great place to ride here in hi, with 400 acres of trails. checked that out yesterday. i plan to use everything that i have from the sled, gonna run it on pre mix to check the oil pump on the first run. then go from there and use it if its pumping good. i gotta get a fuel tank. It does have electric start with a small battery and yamaha ignition, i like that allot.

The rear axle will not bolt up at the moment due to the reinforcing the guy did. i think this is where he stopped. im gonna rebuild the entire rear end, i agree his welds are ugly, but like you said por 15 does wonders and a grinder with wire brush will clean allot of that up. Wanna do the rear suspension simillar to Frankies. Im worndering how the ride will be, i might go with bigger tires on the rear for more ground clearance, and this making it possible for more travel in suspension without bottoming out.

? with the front shocks disconnected from the j arm does the suspension hang? i was thinking about getting some 11" shocks to replace the front. looking to gain travel

? does the sled throttle connection need to be a push or pull cable?

? Are rear reduction boxs different between the years? Ive read the older ones where weak.

I do not have the other lever, im still not 100% on wether i wanna use the levers or get a pedal assy for the throttle and build a pedal from the quad mater cylinder and lever i bought for the 400ex disks and hubs.

Thanks for the help

Heres some pics of the gearbox i plan to use, sled belt, and two different clutchs for the 540. will probably use the yamaha one at first.

? with the front shocks disconnected from the j arm does the suspension hang? i was thinking about getting some 11" shocks to replace the front. looking to gain travel

I would stay with the stock set up. You only have a few inches before the bumpers stop it anyway. Or cut 11" bar and see how it sits? But I would just leave the fron as is. The ody shocks are fine and well built.


? does the sled throttle connection need to be a push or pull cable?

Depends on your carb. Mine was pull just like the ody.

? Are rear reduction boxs different between the years? Ive read the older ones where weak.

81 to 84 has a stronger chain. Look for marks inside the case cover. If any marks on the cover your chain is stretched. There is mods I can find on newer style chain that you can use. Best to use stock 81 up chains.

I do not have the other lever, im still not 100% on wether i wanna use the levers or get a pedal assy for the throttle and build a pedal from the quad mater cylinder and lever.

I have the lever you need and will send it at shipping cost only. $5 flate rate box. I would use the levers for sure. It's so simple and already there. The Ody brakes work good with the little lever. The braking force is multiplied 10 times thru the reduction unit. Odys have very very good brakes. I can stop at full lock up on all my ody's with a slight pinky pull at any speed even on pavement. Plus your feet bounce all over when riding. Also the caliper bolts to the trans and so does your rotor. It's all there so I would just go with it. I have calipers if you need one. I got a junkyard of parts.

I would cut out all the stuff he added. Then get that axle and trans in the original location. Then see what you need from there.

 

[fl250540]

Thats a good point about the pedals, makes sense. i will take you up on the lever, I may have the front brakes run off a pedal and also have the stock. Im gonna have to build a bracket on the carb for the throttle cable, my sled uses push style, should't be an issue. looking foward to getting this project going. i usually have more fun building and working on my projects than when their done. don't plan on selling this one in the future if all goes well. mini sandrails are expensive and take more fab skills than i have to build from scratch. i think this is a great project to build on

Thanks for the advice and help

 

[bighead]

Thats a good point about the pedals, makes sense. i will take you up on the lever, I may have the front brakes run off a pedal and also have the stock. Im gonna have to build a bracket on the carb for the throttle cable, my sled uses push style, should't be an issue. looking foward to getting this project going. i usually have more fun building and working on my projects than when their done. don't plan on selling this one in the future if all goes well. mini sandrails are expensive and take more fab skills than i have to build from scratch. i think this is a great project to build on

Thanks for the advice and help

How does the oil pump work at the carb? Value wise I would try to keep it as close to original as you can. They seem to hold the value better that way. A restored original ody will bring more than most modded ones. Not sure bout the front brakes. I never done that. I do know Ody's stop well as is.

 

[fl250540]

It has 2 lines that go to the intake manifold that pump oil to the cylinders.

 

[bighead]

It has 2 lines that go to the intake manifold that pump oil to the cylinders.

I was wondering how you going to hook both up if you have to mod that part? I prefer using the oil pump for many reason.

 

[fl250540]

The bracket will just be to mount the throttle cable to a pull style, this will not effect the cable for the oil pump, that will stay stock.