emo Project Kujira: My Over-The-Top AZ-1 Build

01 Jun 2017 16:50 #26668

@fxdlidon, it looks like you're right. Here's a picture of the HA21S RS/Z shifter and pedal assemblies.

Of note are the two cables. One is obviously attached to the accelerator but the other one appears to fit into the groove in the clutch pedal. Cable clutch? Not what I wanted but it certainly makes things easier. The last cable clutch car that I drove was pretty miserable but at least I don't have to make brackets to mount a master cylinder, I guess.

Here's the HA21S RS/Z FWD manual transmission. Not my exact one, but the same part. The bar on the far left appears to be the shifter mechanism. Lots of places to bolt a bracket to and very simple twist and in-and-out motion to shift gears.

Because I can, I looked up the HA11S Works FWD manual transmission. This one came in the F6A powered Alto Works. It appears to be an identical unit to the AZ-1 transmission except that it also has the mechanical shifter instead of a cable shifter. Scouring a few parts websites I haven't found any AZ-1 transmissions to do a direct comparison, but I am wondering if I can use OEM parts to convert these transmissions back and forth between mechanical shifter and cable shifter. But like a lot of other things on this project, I will have to put off thinking about it until my car arrives in November. Until then, the focus is on building this new engine. At 120,000km, this engine will receive new everything serviceable. I need a rebuild kit that includes all of the gaskets and bearings and tensioners. I will be getting new pistons and liners for this engine, but I haven't yet found any rods. It seems as though the general consensus in Japan is that the OEM rods are sufficient to handle the extra power that people are throwing at them, but "sufficient" is not good enough to me.

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01 Jun 2017 17:18 #26670

I thought it would be a cable clutch, they all seem to be.
The operating mechanism for the AZ-1 clutch gearbox is on the top of the gearbox but there is a blanking plate on the HA22 box on the top in the same position so the swap may well be simple, you'll only know when you get the 2 transmissions together to compare but my guess is that you will be able to do the swap.
As for a clutch I wouldn't recommend the Suzuki sport one

...that was one track day at around 130bhp!
I never found one that was satasfactory but I never tried the Excedy paddle one - I've got a brand new one that I never fitted, it would need the Excedy high pressure pressure plate.

Last Edit: 01 Jun 2017 17:19 by fxdlidon. Reason: typo

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03 Jun 2017 22:12 #26673

Well that picture is horrifying! I was actually thinking about the Monster Sport metal clutch, pressure plate, and flywheel just because it should be better suited to the torque that I will be making (and because I can order through Amazon), but options seem pretty limited. I see OS Gilken and Exedy clutches available for auction but haven't found much about them because it seems that neither list the F6A or K6A as an available application in their catalogs. I did see that the Exedy pressure plate has a little less clamping force than the Monster Sport one, but there's no info about actual torque ratings beyond Nengun's Monster Sport listing which says that their clutches were designed for 200ps. It doesn't specify which one or even if they're different.

Potentially good news with the transmissions. We shall see how that plays out.

Last Edit: 05 Jun 2017 16:56 by randman2011.

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