Posted on 25 May 2013 at 08:30 pm (CET)
Today I tightened the chain. Usually this should be very easy to do but it took quite some effort here. When the bearing house was in the front position I could see it wasn't possible to take out another link.
But when I turned the bearing house as far as possible backwards the normal way the chain still wasn't tight enough.
It was also very difficult to turn the bearing house. I was even unable to move it at all at some point. The cause of this turned out to be the plate that the brake caliper is attached to. Took this off and it was a lot easier to turn the bearing house. Just still not far enough to tighten the chain. But after that I did still find a way to tighten it a bit more than is possible the normal way. I attached the brake caliper's plate again but outside of the part that keeps it in place. This way I could turn the bearing house just a bit more. And it turned out to be just enough, the chain is tight now.
But there's still a problem, I saw that the chain isn't sitting in a straight line. This will still have to get fixed, probably with an adaptor so I can move the rear sprocket a bit more towards the swing arm. I can't move the front sprocket any more to the outside because of the frame. What could be an even better idea is to turn the current sprocket into an adaptor and get a new sprocket from a known brand. This way it'll be a lot easier in the future to get my hands on a new sprocket instead of having a custom one made again.
Today I was able to continue building. I received the adaptor and sprockets. They all fit perfectly.
Also checked how the chain would fit. Could shorten it quite a bit.
Took a while to shorten it since I don't have the tools for this but I succeeded anyway.
Now it just needs some more tension but it was getting a bit late already so I'll do this tomorrow. Could be that I still have to take 1 link out, not really sure if I still had the bearing house in the front position. It has quite a bit of play right now. But from what I can tell the chain is sitting in a straight line, didn't even have to adjust the adaptor. It just sits all the way on the axle.
Good news after today! The motor is finally attached to the rear swingarm. The blocks were TIG welded onto it and it looks very nice. The welder also said that this weld would never crack. And even if it did, I could return to him and he'd repair it for free. So I think it's safe to say that it's definately sturdy enough. He did say though that the original welds on the rear swingarm weren't so great and those could crack some day, but well it's a Chinese quad bike so you never know what to expect.
Here are some pictures.
On the bottom the rear block was welded entirely as well, only the front block is welded about halfway since he couldn't reach it that well. But it's sturdy enough anyway. Don't really expect to ever get any problems with this.
I also attached the rear swingarm with motor back to the frame again. And then I came to the conclusion I was very lucky with the welding. Between the motor and suspension is only about 2 mm of space. Thought I'd have a lot more space there. But I'm in luck, it's just enough. And when the suspension compresses the space only gets bigger so no problems with that either. This way I only have more space to place the charger and the batteries so it's all good.
Now to wait for the adaptor and sprockets.
When I wanted to attach the rear swingarm to the frame again I suddenly saw some brake fluid on the floor. The hose between reservoir and brake pump was all wet. So I removed it to take a look. It's very small rubber en apparently not really resistant to dot 5.1 brake fluid. For now I replaced it with a fuel hose but I'll have to get something else for this.
Today I removed the paint of the rear swingarm on the spots where the blocks will be welded and the mount will be sitting. Did this with a steel brush drill bit, went pretty good.
Tomorrow hopefully a picture with the motor finally attached on there. I will probably also get the adaptor and sprockets this week.
Today I got the motor mount and the blocks back. The adaptor and sprockets aren't ready yet, will probably still take another week.
Everything fits well now and both of the blocks are now sloped which looks a lot nicer than such boring straight blocks.
Only a small problem because of the bad welding by the Chinese. On the rear there's quite some play between the blocks and the swingarm. On one block it's around 0,3mm and on the other 0,7-0,9mm. Wonder if this really matters to get it welded properly or if I'd have to add very small plates inbetween.
In any case I already contacted a welder nearby, going to wait and see what he says about it.