Apart from the mounting and triggers are the two flywheels the same ???
That's to say I could use the 4JH stator and pickup with the modded 3tj flywheel.

This sounds good.

The plot thickens
Welding new triggers on will work as will replacing the flywheel centre. I would go with the first option to avoid the possibility of the rivets being incorrectly fitted or machining errors on the new centre. Avoid any spacers or adapters. The flywheel is a big hunk of metal spinning up to 13000 rpm or so. Its diameter will magnify even the slightest machining error. Last, but not least, have the flywheel rebalanced.

Ok got some pics for you,



The first pic is of 3he rotor,
The second pic is 4jh rotor.

You could remove the centre from the 3he,and fit it to the 4jh rotor.

That sounds good

Right then.
Movement ... forwards movement too.
I've sent a 4JH + 3HE flywheel to BDK for some engineering action.

The crank oil seal
The 4JH has a locating lip on it but the internal dia is to large. The 3HE seal's outside dia is too small. Ronaldo at college made the observation that the 3HE seal nearlt fit's inside the 4JH one ... and you what it nearlt does
So, given neither of them can be used and time is pressing he persudaded me to give in a whirl. We took the 4JH spring out then used a vice and pressed them together, it took the rubber face off the outside of the 3HE but they were there. We cut the excess of 4JH and offered them up. The back of the 3HE overhung the 4JH locating lip ... so Ronaldo filed it down. It aint pretty but it looks like a useable seal


We got the rods on too, cleaned the cases mating surfaces and dropped them together. They actually fit quite easily, much better than the college engines.



I'm away if Belgium / France over the weekend so the next instalment will in a weeks time.

Coming along nicely EC.
Now about your FrankenSeal. You know it is up to us your beloved followers to ensure quality control.
I think it was Hunter that said a 24x40x8 seal is what you needed? Is that incorrect or could you not acquire one?

I'm sure he's right but there's a locating lip on the 4JH seal and as neither could be used and they were there we thought we'd give it a go. I measured up the seals so I can post up a drawing later down the line ... or order the propper seal when this one fails I have very little time left at college so needs must when the devil drives

Hi there
This sounds quite interesting, but due to my trouble understanding mainly technical english, and english in general i think i did not figured out exactly what you want to do.
You want to do a 660ccm conversion with an 3HE cylinder, 3HE pistons, FZ6 crankshaft and piston rods and 4JH TCI and electrics?
I think I can remember such a conversion in our german FZR forum, but i don't know what the real effort in the end was.
Greetings from Germany and congratulations on your wedding
Marcel

Hi Marcel,

The original conversion was to use a 3HE engine with 4JH pistons and cylinder block, but this used 3HE electrics and needed a spacer gasket under the cylinder block to account for the length of the 3HE con rods.

The conversion that Boris is attempting and that I will be doing this winter, is to start with a 4JH engine and swap out the crankshaft from a 3HE and the con rods from the FZS600 fazer, the FZS rods are the right length so there is no need for the spacer gasket. As the crankshaft has the 3HE flywheel and trigger points, the challenge is to change the flywheel to one that mimics the 4JH and will let us use the complete 4JH electrics.

This should give 660cc and about 15-20bhp extra! Lots more torque too...

Alex.

Nice
Please update us on the effects