Kat's Volty two-fiddy Street Tracker

GoodKat · 2020-12-05T23:23:04-0500

Ok, so I gotta take a break building this because of COVID - 19.

Everyone in the household has it. Even tho we limited the public exposure, ALWAYS wearing masks in public (mandatory by law) and keeping social distancing as much as possible, somehow it got to us.

Muscle aches, runny nose, fever and a cough. FUUUCK!!!

Bandit1052 · 2020-12-08T14:11:32-0500

I wish you a speedy recovery in overcoming this insidious disease.

GoodKat · 2020-12-08T15:50:11-0500

Bandit1052 said:
I wish you a speedy recovery in overcoming this insidious disease.

Thank you so much, sir! Everyone feels a little bit better than few days ago, no more fever, only the muscle aches and general bad disposition, but this is not that serious.

GoodKat · 2021-01-05T17:12:37-0500

Back in business.

Today I managed to put together the rearsets and the brackets I've made.

It's a first time for me, everything was made from scratch.

Not perfect, the left adapter bracket warped a bit when the final welds were made, I'll massage it back, but I am pretty happy about the results.

Still need to finish them.

host image

Mattson · 2021-01-05T17:27:36-0500

I like the looks of that (stores the idea to be stolen on some future project)

rex_saugerty · 2021-01-05T23:51:15-0500

Thats a neat idea

GoodKat · 2021-01-06T00:46:18-0500

Mattson said:
I like the looks of that (stores the idea to be stolen on some future project)

Can't wait to finish them. The pictures are before final welds. I paid a welder to TIG them for me. When I got home, I did a test by bolting one to the frame and let my weight on it and it holds me, so everything should be safe & sound 😁

Now...just need to remove all the burrs and give them a good clean.

GoodKat · 2021-01-11T13:52:58-0500

Finished the shifter side linkage. Shifts smoothly, 0 binding, pretty happy about how it turned out.

Stainless steel hardware, bolts, shift rod, adapters.

Now...let's see how the brake side will turn out...

GoodKat · 2021-01-12T04:59:12-0500

Here's a little video showing the shifting mechanism in action.

GoodKat · 2021-01-14T17:41:22-0500

This evening I did some work on the brake side. This is a trial, this is not the final form, I need to improve the design but now I got some clear lines.

Things to improve:

increase the thread diameter from 6mm to 8mm.
make the bends near the mounting points so the bending angles are not as sharp, will help by reducing any flex since a straight rod cannot be used.

Also I did the torque arm out of 5x30mm stainless flat bar.

GoodKat · 2021-01-15T18:19:48-0500

Today I did this clevis rod end out of some stainless flat bar and a long nut.

Took me the better of two hours, now I think I would be able to make it faster, but if I would have the chance, I would buy it...the problem is that I don't know where I could buy it from.

Probably a machine shop could make some pretty fast, I don't need them to be finished, I can do that myself. Only two holes (8mm thread for the longitudinal hole) a 6mm hole for the transversal one and a 5mm wide slit for 30mm or so, but no one is willing to do just a few.

GoodKat · 2021-01-16T16:00:13-0500

Today did some work:

Made a new brake rod out of 8mm stainless rod, with new angles, a safety pin for the clevis rod end, also stainless, and this drum arm plug, also stainless.

Comparison old vs new:

GoodKat · 2021-01-16T16:03:22-0500

GoodKat · 2021-01-20T14:48:00-0500

Today I've finished the rear brake, seems to work as expected.

& Built the front mud guard mounts:

GoodKat · 2021-01-22T16:57:09-0500

Today had only one hour of work time, so I did something small.

I wasn't happy with the rear brake lever knob, so I've made some kind of a pedal tip to bolt to the lever.

A bit of stainless, from this:

A bit of filing, to this:

GoodKat · 2021-01-26T13:56:43-0500

PLEASE HELP:

Ok guys, time to put on the think hats.

I got this weird issue that I cannot figure out the root cause.

So,if I torque down the rear axle nut, the wheel starts dragging if I try to spin it.

What I surely know:

I've changed all the bearings (wheel and sprocket carrier)
the sprocket carrier is from a GN400 (compatible part)
the brake shoes plate is from a GS450 (compatible part)
the bearings are flushly seated
the spacer in the wheel hub (between the left and right bearings) still can be moved if you...finger it....through the inner bearing race.

- What I've noticed: it seems that the brake shoes plate touches the lip of the wheel hub when torqued and this causes the drag along with a "shhh" noise that is cyclic when the weel is spinning.

I do not know what I'm doing wrong but this thing makes my head itchy... My guess is that when I torque down the axle nut, the drum plate presses on the right side inner bearing race thatmoves a bit on the inside until it hits the spacer.

QUESTION: The wheel bearings must sit flush on the wheel inner spacer? Should I be able to move if with the bearings fully seated?

GoodKat · 2021-01-26T13:58:56-0500

GoodKat · 2021-01-26T16:45:21-0500

Had a thorough look on the microfiche and it seems that I'm missing a left side spacer. I hope that this is the culprit.
Anyone in Europe having this Suzuki part number? 6473333000 was used on a lot of Suzuki models:

Kat's Volty two-fiddy Street Tracker

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