[Gixxerbuggy]

New guy, first post. I'm looking for some help. I have put an 04 600 engine in my offroad buggy and need to make a counter shaft extension so that I can move the sprocket away from the engine for clearance to run large sprockets up front due to gear reduction in both the bike transmission and the buggy transaxle. The machinist I'm working with is looking for the DXF file for the splines on the counter shaft so that he can cut them into an extension that will slip onto the shaft just like the sprockets do. I have not been able to find this info, any help would be greatly appreciated as this is the last piece for the puzzle needed to get this buggy usable.

 

[TheGeek]

So you want to speed up the input to the buggy transaxle?

 

[Gixxerbuggy]

So you want to speed up the input to the buggy transaxle?

Yessir that's correct.

 

[TheGeek]

I'd recommend a jack shaft rather than trying to extend the output shaft. Trying to maintain center would be very difficult. You should use a drive coupler (example below). Much easier to machine, and the dampers would provide multiple benefits to the entire system.

https://weberpower.com/parts-weber-mpe-750-mpe-850-billet-drive-coupler-kit.html

 

[Gixxerbuggy]

Geek thanks for that link. I'm interested in anything that can/may work. I've seen the extension work when done properly. I don't have alot of room to work with that's why I've been trying to find an alternative to using a jackshaft setup.

 

[TheGeek]

Jackshaft would make placement easier and give you the ability to tension the primary drive chain. Mechanically the extension is going to put a lot of load on the bearing unless you support it outside too. I think the blended design with the extension being supported on it's own and using a coupler would be the best idea. Space wise, you're only talking a couple more inches outside the normal width of the engine.

 

[Gixxerbuggy]

Jackshaft would make placement easier and give you the ability to tension the primary drive chain. Mechanically the extension is going to put a lot of load on the bearing unless you support it outside too. I think the blended design with the extension being supported on it's own and using a coupler would be the best idea. Space wise, you're only talking a couple more inches outside the normal width of the engine.

I agree that the jackshaft setup could be the easiest option. I will be supporting the extension on the end with a pillow block. I just started working with a machinist that builds buggies for a living. We are both thinking along the lines of an internally splined coupler that slides over the counter shaft as you're describing.