Shaft Extensions

[Tweezer]

pulled the trigger on a new engine from overseas, a bit of a leap, but I want to give my TW200 a proper power bump and a 6 speed transmission. My goal? keep the oversized rear sprocket for that off-road grunt, but still cruise comfortably on pavement. The real puzzle now is figuring out how to extend the output shaft so it lines up clean with the rear. Anyone here have insight on custom shaft extensions?

 

[isleofmantt1]

I doubt it's gonna be a smooth swap, but I wouldn't say it's impossible. You'll need some custom fabrication for the shaft extension and make sure you use quality materials and align everything perfectly

 

[BurningFlame66]

Tried something similar before, I went to a local shop and they made a part that connected everything and kept it steady. Have you checked out spline adapters or bolt-on extenders? They might work if the sizes match.

 

[DorkOnWheels]

pulled the trigger on a new engine from overseas, a bit of a leap, but I want to give my TW200 a proper power bump and a 6 speed transmission. My goal? keep the oversized rear sprocket for that off-road grunt, but still cruise comfortably on pavement. The real puzzle now is figuring out how to extend the output shaft so it lines up clean with the rear. Anyone here have insight on custom shaft extensions?

How's the project coming along? It sure is ambitious but I imagine a 6-speed TW would be awesome! The biggest challenge with these engine swaps is definitely the sprocket alignment, and the most common solution is a custom-machined adapter plate that bolts onto the new output shaft, effectively extending it. A local machine shop could likely make one for you. A more complex route would be a bearing-supported jackshaft, but the adapter plate is the more straightforward approach.

 

[Alan]

@Tweezer That’s a bold project! A custom-machined adapter plate is usually the cleanest way to extend the output shaft and keep everything aligned. A local machine shop can handle it, and it avoids the more complex bearing-supported jackshaft route. How’s the engine fitment looking so far?