Making of the 10HP Diesel Prime Mover

Discussion in 'Some Assembly Required' started by danielson, Jul 11, 2010.

  1. danielson

    danielson Adventurer

    Joined:
    May 30, 2009
    Oddometer:
    83
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    Adelaide, Oz
    Hey all


    Thought I might show this short build of a Diesel powered motorcycle

    The Diesels a 418cc 10HP lump. A clone of a Yanmar made by our Chinese friends.

    I've been told by the importer these are the better clones using quality injector, seals and bearings (maybe SKF or FAG?).
    Time will tell.

    I used an Enfield as the donor bike. They aint that cheap these days but the parts are and widely availability. Thanks Indians:D probs won't last forever though.

    As the whole setup originally has the petrol motor as a stressed member, we went with the original design and made the Diesel as a stressed member too


    [​IMG]


    Had to purchase a Renold 25 tooth duplex sprocket to go on to the output shaft of the Diesel. Its in the BRH corner

    Local machinist got it bored out 1" with a 1/4 key way to fit.

    A hole was tapped, threaded to fit a grub screw to grab onto the key steel.

    [​IMG]

    First off had to make a backing plate on the gearbox using 5mm steel, 400 by 100 for $7, what a rip off.

    2 holes were drilled at opposite sides on the gearbox plate, to make 4.

    At the back of the motor is the governor linkage (throttle), it's the beta version, I made an improved one later.


    [​IMG]

    Leveled the rear bracket, placed the motor on it at proper height with the front bracket. Welded on triangles to bolt to the front down tube.

    Front bracket made from 6mm steel with 6mm triangles. $10 for 1000 by 200 wide 6mm thick, baargain!!



    [​IMG]

    My bro did all the important stuff; the welding, I did all the cutting, grinding, made throttle and engine kill cables and other bits and bobs.



    [​IMG]

    [​IMG]


    Had to measure out accurately the 3 holes to drill in the inner primary to bolt onto the motor.

    The Diesels output shaft is the same distance from the gearbox shaft as the previous petrols.

    Didn't have to alter primary chain at all.

    Just eyeball it with the clutch basket sprocket bolt the grub down and your good to go.




    [​IMG]

    [​IMG]

    That's me ugly mug in the Jackie Howe



    [​IMG]



    All fitted.

    Painted the flywheel cover black

    Later cut out the all important head steady to get welded.

    Can see in the pics below.

    [​IMG]

    Pre units are great

    [​IMG]

    [​IMG]


    And out in the country

    It should hold up well, currently 700kms on it.

    Dan
    #1
  2. neilaction

    neilaction Slightly Less Adventurous

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    Nice work.:clap Keep us posted. :deal
    #2
  3. woody's wheel works

    woody's wheel works Built to Last

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    kudos to the two of ya:super

    here's another mate of yours down under,,,,a kindred spirit who thinks outside of the box:

    OBTW,,,don't let the thread title mislead ya:wink:
    http://www.advrider.com/forums/showthread.php?t=311887&page=9

    looking back over the years, i have always been impressed bu the QUALITY of the work as well as innovation coming out of ozzieland and NZ....perhaps it arises out of the fact ya don't have everything at your fingertips:dunno

    a green tinny or darwin stubby to ya
    :beer
    woody

    FYI,,you two have buildt a machine that in a way is very future thinking,,,,,because the wave of the future [starting immediately] is how to conserve ,,,how to recycle,,,how to build longlasting devices,,,how not to get sucked into consumerism and planned obsolesence,,,

    you guys are on your way,,i'd open my work-shop any day for you all to tinker in:thumb
    #3
  4. BikePilot

    BikePilot Long timer

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    Great work:clap

    I'm curious what sort of fuel system the little diesel uses (guessing a mechanical pump and indirect injection)? I bet there's a ton more power to be had if you can squirt a bit more in:evil An industrial engine is probably limited such that EGTs won't get crazy if run WOT continiously. On a motorcycle you could get by with a lot more fuel for a short amount of time without melting stuff I think:evil

    What's it like to ride?
    #4
  5. Clancy

    Clancy Long timer

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    Love your work:clap Great vision.
    #5
  6. DRjoe

    DRjoe Long timer

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    Hats off to you for building that.
    But you realize what you've started, There are now a crap load adv riders searching the classifieds for an old pre unit bike. Me included.

    How much has the finished bike cost you?

    I used a yanmar clone to build a hydraulic power pack for my brothers crab boat.
    The build of the motor was really impressive for being so cheap.
    The strange thing was it really didn't like getting wet I mean just a splash of water over it would cause problems so maybe a better cover over the air filter and some sort of muffler would make it usable in the rain.
    #6
  7. FatBoyCrash

    FatBoyCrash Buckle up SpankY!!

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    Mate!! Top effort! Any chance you could give some more details on the donk? Like name and who where you got it from??
    #7
  8. pugsley

    pugsley Little Man

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    Nice one Fella,Great Job!
    #8
  9. WILL_S

    WILL_S OUTLAW POSTIE 001

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    Well done.:clap
    Now where's that old pre unit frame and box i got laying round.
    #9
  10. kiwipeet

    kiwipeet Uber Cyber Loafer

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    Thats a great bike. :thumb

    I'd love a wee pokka pokka bike like that for myself. I find myself looking far too often at BSA bantams... Hmmm a diesel beesa banty....
    #10
  11. Mickldo

    Mickldo Been here awhile

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    Maryborough, Qld, Australia
    #11
  12. danielson

    danielson Adventurer

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    Adelaide, Oz
    Thanks heaps all for the coms

    Thanks woody, that's exactly what the plan was, one may say 'a bike for life' providing the motor keeps going.

    Bike Pilot the motor is direct injection. Yep its got a mechanical pump.
    I don't about getting more grunt as I've read its a fixed timing motor, its best run a constant 3000 or any other.
    What I have seen is people whack on small turbos on these 10HP motors, I don't know bout reliability though.
    Heat wise its got a big fan on the flywheel forcing air on the cylinder and head. So the motor gets cooled twice while riding. I don't think it'll overheat.

    If you have ridden a 50s British single, its just like it.

    Yeah Joe I wish I didn't post this, now all pre units will dry up:lol3

    Costs all up around 4000 bike included

    Yep the motors good for the price. I haven't ridden in heavy rain yet just light, no problems. Interesting though.
    The airfilter is nicely covered.

    FatBoy

    Here's some stats

    418cc 86X72
    10HP @ 3600rpm
    26Nm 1500-3500rpm

    Bought from
    Tool Power on Epay, a Melburn mob

    Peet
    Bantams are unit construction I think. I reckon B33, B31, M20 or 21 from the Beezas would be good candidates.
    You'd want at least 4 speeds.

    There are other options, getting a an sheap old japper with a 6 speed, 80s CB250 superdream or the like, cutting the gearbox out and making a separate casing for it.

    And you have yourself a nice gearbox. Sounds like a lotta work. This has been done before.

    Hey Mick

    Yep great site that, lots of good bikes



    A few more from todays ride

    900kms clocked up so far, running well:D

    [​IMG]


    [​IMG]


    I'll have a few vids soon
    #12
  13. clarky

    clarky 05' 640 Adv

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    Fantastic work Danielson, love it :clap

    What sort of economy are you getting, have you had to use anything other than the oily rag stuffed into the intake :rofl
    #13
  14. danielson

    danielson Adventurer

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    Clarky mate thanks

    I thought I'd get that question first:D

    Currently at 55km per liter, so 1.8l/100km

    That figure might improve after running in

    Comfortable range of 700km with the current 13.5 liter tank
    #14
  15. mcfear

    mcfear now known as many things

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    who the hell knows these days :D
    far out thats good.
    whats the top speed like?
    #15
  16. icekube1

    icekube1 Middle aged git

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    Bloody brilliant bit of work. You should go into production.. I'd buy one:deal

    What's it like on the kick starting?

    Has it got a charging system?

    Are there many vibes....would you be prepared to run a full tank of fuel through it on a day ride?
    #16
  17. kiwipeet

    kiwipeet Uber Cyber Loafer

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    :huh

    So stick a Safari tank on it an you could go 1700k's before reserve :lol3
    #17
  18. FatBoyCrash

    FatBoyCrash Buckle up SpankY!!

    Joined:
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    See these two pics? For me, they sum up quintessentially what motorcycling is. And should be. 35k dirt bikes and GSXRRRRzzzRRRR crotch rocket be stuffed.
    Two blokes, in a shed, wearing bluey singlets, armed with arc welder built a bike. And behold it was good. Then he went riding. Mate, your good for a camp if you ever hit Brisvegas!!
    #18
  19. Adrian V

    Adrian V Been here awhile

    Joined:
    Jul 15, 2008
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    525
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    Albany Western Australia
    Looks like it was always meant to be there doesn't it :clap .

    Dan,

    Was it more difficult to do the conversion without using an adapter ring, the Taurus inner primary chaincase and the longer transmission mainshaft? I note you said careful measurement was needed to drill the holes in the inner primary. Was that the standard petrol inner primary? 350 or 500?

    thanks,

    Adrian
    #19
  20. ADVJake

    ADVJake ***** dweller

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    i want one... what amazing fuel economy.
    how much it cost all up to build?
    #20