Honda Odyssey FL250 to Yamaha 340 Sled Power Conversion

[bainer1290]

Bighead we need to chat!!!

I'm working on a very similar project Odyssey with an older Polaris 440, interested in your driven clutch setup...

Here's a pic of my project, not to hijack your thread, just want to share with a fellow Odyssey builder!!!!!

 

[bighead]

Bighead we need to chat!!!

I'm working on a very similar project Odyssey with an older Polaris 440, interested in your driven clutch setup...

Here's a pic of my project, not to hijack your thread, just want to share with a fellow Odyssey builder!!!!!

Interested in your suspension as well. What driven do you have now? Mine is stock Ody. I am doing some machining work to the drivin clutch cam to match the belt size. Basicaly machine 3/16 of the cam face.(where the snap ring sits) This will widen the driven clutch for the large sled belt. The machining does not change how the drivin works. Some use spacers but that changes things I think.

What driven do you have now? Have you seen my other ody's? I have a few of them.

http://www.youtube.com/watch?v=CUq6DBpzRRs&feature=mfu_in_order&list=UL

http://www.youtube.com/watch?v=dCMuwGDdJKY&feature=related

 

[bainer1290]

You bet I saw your whole thread looks like you have quite the collection...

As for the rear suspension, it is setup to pivot right behind the seat, basically the whole engine cradle/rear end can pivot from that point, works pretty good. I got some big quad shocks on the back right now, they are way too stiff, I need to get some lighter ones so it has some more movement, but trying to get it to run properly first...

Right now I am just using the stock Ody driven with a stock Ody belt, but the problem is the Polaris primary uses a 1 3/8 belt and the Ody belt is only 31/32 so I want to try your trick and take 3/16 off the cam. This will allow me to use a wider belt, what width of a belt are you using now? I would love to be able to get a 1 3/8 gap but that might need to be done with some spacers too or a Comet D90. Problem with spacers are they open it up wider to begin with but you have the same max width at the end, meaning the driven can still only open so much, your trick is great because it increases the max opening of the driven.

 

[bighead]

As far as the belt size I am not sure. I gave the specs at Pilotoodyssey.ccom. They told me to take 3/16 off the cam face. And add a 3/16 O-ring as a spacer.

 

[bainer1290]

I see so the o-ring acts like a shim between the two faces of the driven clutch?

 

[bighead]

I see so the o-ring acts like a shim between the two faces of the driven clutch?

Yes Sir. The o-ring acts as a spacer not to pinch the belt.

 

[bighead]

Bighead we need to chat!!!

I'm working on a very similar project Odyssey with an older Polaris 440, interested in your driven clutch setup...

Here's a pic of my project, not to hijack your thread, just want to share with a fellow Odyssey builder!!!!!

Can you post some pics of you rear suspension? Really would like to check it out. Also how does it run now with the belts the way they are? Thanks

 

[bainer1290]

So where did you find a 3/16 o-ring? And what diameter was the hole in it? That's a big o-ring haha

 

[bighead]

So where did you find a 3/16 o-ring? And what diameter was the hole in it? That's a big o-ring haha

I have not done this mod to my buggy yet. I will start this by next week I hope. Still waiting on pullers.

I will find my thread where I asked and got my advice from.

 

[bainer1290]

Sounds good let me know and I will do the same...

 

[theo]

I will find my thread where I asked and got my advice from.[/QUOTE]

Big head, did you happen to find this thread?

 

[bighead]

I will find my thread where I asked and got my advice from.

Big head, did you happen to find this thread?[/QUOTE]

This thread?

 

[glb7]

I have not done this mod to my buggy yet. I will start this by next week I hope. Still waiting on pullers.

I will find my thread where I asked and got my advice from.

he means that i think

 

[bighead]

There are 3 ways to do that I know of. Post #4 looked like more work. I like post #5 the best. It would be real easy to pull the cam off and take off 3/16. It would not change any of he moving parts. Just widen it for the snap ring would be moved in letting the faces spread apart. It is on a keyed shaft so plenty of room to move.

http://www.pilotodyssey.com/PO/viewtopic.php?f=1&t=8291

For anybody wondering I am talking about. I will be taking 3/16 of the cam face. Right where this snap ring is. If I machine 3/16 of that part. The whole unit will slide over making the clutch faces wider. I see no reason why it would not work. Look at my last pic. You can see how the whole right side would slide over to execpt wider belt. My machine shop quoted me $25. I would amagine it's a simple job for a shop.

I may have to machine some off the surface of the cam (where the 3 holes are) so the washer and bolt sit flush. Have to keep an eye on that. So 3/16 of the snap ring surface. And 3/16 of the 3 hole outer surface right?

Also double check the 3/16. I am using that number just from what one guy said. So do your own math.

 

[bainer1290]

Makes sense, I am going to pull my secondary apart this weekend and see what it looks like, let me know how yours turns out. Thanks for the info.

 

[bighead]

Makes sense, I am going to pull my secondary apart this weekend and see what it looks like, let me know how yours turns out. Thanks for the info.

What shocks do you have on the front of your Ody?

Also what tool do you use the pull the cam off? I already broke one cam. Ops

Here is a parts pic. As you see the cam slides on the key shaft. Pretty sure this will work. Also can you adjust your sleds primary clutch? If so you should be able to dial in the clutch. Have you seen the aftermarket springs and bottons for the drivin?

When putting back make sure your spring is locked into the tabs that hold each end of the spring.

 

[bighead]

Here is a great read on clutching. Must read.

Optimizing belt fit in the clutch system

http://www.gates.com/brochure.cfm?brochure=1034&location_id=3850

Another good read. But this is how I busted my cam. This puller snapped the cam right off. Could you drill and tap the 3 holes? You break it the cams are $50. I am going to have my father in law try to make a puller and tap the 3 holes. 3/8 steel plate puller. Tap the holes with fine threads. I got a broken cam to play with.

http://www.kartpowersports.com/honda-odyssey-cvt-rear.htm

 

[bainer1290]

Front shocks are off an 88 Yamaha YFM 350 quad, had to make different mounts on the J arms and the frame so they would fit as the eyes are wider...

The drive clutch on the Polaris engine can be changed by adding a stiffer spring or different weights, will have to do that once I get the wider belt on to make it run good. Where did you find the aftermarket springs/buttons for the FL250 driven?

I'm going to try to pull my cam in the next few days, I'll let ya know how it goes I figured it would just slide off, but looks like that's going to be a dream.

 

[bainer1290]

Was able to get the cam pulled off, had to use a puller there was 3 holes drilled in mine so just tapped them out and used a puller and the impact, worked well.

I am going to need to get new buttons for the cam and maybe a spring, probably could use it since it is 30 years old haha

Where did you find them for sale?

 

[bighead]

Was able to get the cam pulled off, had to use a puller there was 3 holes drilled in mine so just tapped them out and used a puller and the impact, worked well.

I am going to need to get new buttons for the cam and maybe a spring, probably could use it since it is 30 years old haha

Where did you find them for sale?

Odysseysalvage .com is where I would start. Ebay has the bottons for sale. Maybe the spring.

I also got the cam off today by taping the 3 holes. Looking at it now. Looks to be plenty of room to take off 3/16.

Have to checked the math? No way can I figure that stuff out. Hoping some other will chime in here on the subject of maching the cam and how much space you need.

Confirming my belt sizes now.