97cc Seagull
Posted: Fri Jan 12, 2018 10:43 pm
This is a project I've picked up and put down several times over the past few years so a lot of the details are forgotten or sketchy but still some of you might find it a quirky project.
In looking to make a 'gull go a tad quicker on a budget, I kept tripping up on the limitations of the bottom end. The solution I couldn't stop considering was to install ball bearings where possible and do away with the plain bearings which, at least on all of the bits I was willing to throw at such a project, were past their best (at best!)
That idea was dead in the water pretty quickly for heaps of reasons so I had a look about at small Japanese bottom ends. Not an idea any purists would consider and probably not kosher among racers but could be a fun engineering project.
It seemed like there were potentially some that might be shoehornable into the space with the same or a similar stroke to the 102. A few £ on eBay got me a spares honda crank, I think it was from an SA50, PC50 or similar.
It turned out to have a slightly shorter throw than the 'gull which was a bit annoying as it brought the engine cc back down to ~97cc and also mean some serious skimming of the barrel and head.
Had to slim down the flywheel a bit and grind some clearance in the crankcases as well as obviously machine recesses for the bearings - who knows how the not fully supported bearing races will fair!
Ended up with one reasonable ball bearing on the beefier lower side and two quite flimsy bearings in the thinner casting at the flywheel end. Above and below the main bearings, I put needle rollers. A comprise, especially as they run directly on the machined, unhardened steel of the honda crank.
The piston was a bit of a head scratcher, I decided I'd have to use an original piston but mounting it was going to be tricky considering the honda little end was expecting a 10mm gudgeon and needle rollers. In the end I pressed in some spacers and reamed them for the 10mm pin. A lot of weight on the end of con rod considering it was designed to take a 50cc piston!!
Filled the head (a lot) and did my best to go through Jennings and another manual (name forgotten) but it's all a bit outside of the scope of such publications written with much higher rpm and loop scavenged engines.
Fitting a press together bottom end freed up lots of space in the crankcase which was filled to what I decided, based on some careful measurement, was a sensible degree.
Some disorganised pics to follow
In looking to make a 'gull go a tad quicker on a budget, I kept tripping up on the limitations of the bottom end. The solution I couldn't stop considering was to install ball bearings where possible and do away with the plain bearings which, at least on all of the bits I was willing to throw at such a project, were past their best (at best!)
That idea was dead in the water pretty quickly for heaps of reasons so I had a look about at small Japanese bottom ends. Not an idea any purists would consider and probably not kosher among racers but could be a fun engineering project.
It seemed like there were potentially some that might be shoehornable into the space with the same or a similar stroke to the 102. A few £ on eBay got me a spares honda crank, I think it was from an SA50, PC50 or similar.
It turned out to have a slightly shorter throw than the 'gull which was a bit annoying as it brought the engine cc back down to ~97cc and also mean some serious skimming of the barrel and head.
Had to slim down the flywheel a bit and grind some clearance in the crankcases as well as obviously machine recesses for the bearings - who knows how the not fully supported bearing races will fair!
Ended up with one reasonable ball bearing on the beefier lower side and two quite flimsy bearings in the thinner casting at the flywheel end. Above and below the main bearings, I put needle rollers. A comprise, especially as they run directly on the machined, unhardened steel of the honda crank.
The piston was a bit of a head scratcher, I decided I'd have to use an original piston but mounting it was going to be tricky considering the honda little end was expecting a 10mm gudgeon and needle rollers. In the end I pressed in some spacers and reamed them for the 10mm pin. A lot of weight on the end of con rod considering it was designed to take a 50cc piston!!
Filled the head (a lot) and did my best to go through Jennings and another manual (name forgotten) but it's all a bit outside of the scope of such publications written with much higher rpm and loop scavenged engines.
Fitting a press together bottom end freed up lots of space in the crankcase which was filled to what I decided, based on some careful measurement, was a sensible degree.
Some disorganised pics to follow