Suzuki RF400 project, original gearbox, commuter, brushless

[marcexec]

Yes.
I intend to keep it simple at first. There is no point wasting half an hour to remove 100g of aluminium when I am putting in lead acid batteries elsewhere (for the moment).
The clutch will stay wet as it was that way before and leaves me with the old filler cap for oil inspection.

[TerraRoot]

i see what you mean about only a few grams saved, however i reckon there's more then that to be saved, wet clutches create drag and having it out in the open will cut that out and allow you to directly attach the motor via the belt to the clutch, which will save you that 880g worth of quartered crank, and with that gone there's no shell bearings left then and you can dump the oil pump. the gears will be fine in a oil bath. need a few bearings with seals tho.
it'd probably be ok, but i'd worry with only a few horses i'd want to cut out any drag/losses.
just noticed your from dublin, in my best tommy tiernan corkman accent "I'm from cork boi!"

[marcexec]

Well I'm halfway through the blanking/closing plates fitting.
It proves to be a tedious process as I have to cut a groove in the block, then saw and file a piece of sheet metal to fit tightly.
I rather do this properly as I can't have an electric bike leaking oil...
BTW, oil pump will stay out as well

In the meantime some goodies arrived, hope you like them

Anyone knows what that is?

[marcexec]

Finally something to look at regarding the gearbox:
Before

and after


Still one cover and 4 blanking plates to do...

[marcexec]

The project is still alive - ordered the 3 12mm shafts to be made at an engineering shop.
Will be a little bit expensive as they are using the good, hardened stuff and have to add a finishing touch to the cog.

I made a little drawing for the order I'd like to share.



This had to wait until I was finished making all those blanking plates to keep the oil in the transmission - time consuming and tedious, especially as I want it done "right". I estimate an effort of 80-100 hours going in the transmission after it was pulled apart:
- cutting it open
- fabricating the motor mounting plate
- blanking and cover plates, and all those grooves

In retrospect, I would advise using a transmission that's sealed more easily like shaft drive or 2-stroke.
I will have more updates soon.

[Mugge302]

Hello, sort for using your threath.

But i see you have taken a rf400 gearbox apart. Do you know Where to get a new/used gearbox, as mine is jumping out og 2. Gear. Or know how to replace it. What is needed When assembling it again? (Gaskets, seals, or so ón)

Thanks a lot and sorry again.

Best regards, Bjarne from Denmark.

(Suzuki rf400 1993)