FFuture

Suzuki Burgman 400 Kit

The second possibility for an FF Commuter kit is to base one on one of the Megascooters. The Suzuki Burgman 400 looks like a particularly worthy possibility. Although only just released, it has many qualities that make it very attractive as the basis for a Commuter FF Kit. Here's some pictures of the standard bike with and without it's clothes.

We have a couple of problems here.

First the carburettor and airbox can just be seen and the top of the carb gets in the way of where we want to sit. It might be possible to reverse the manifold but there's not much space that side either. In reality, if we just use a thin seat cushion and are careful with space, it should be possible to get the seat height down to 24" which is probably enough. A downdraught carb and different airbox arrangement might help followed by cutting the seat rails but this introduces all sorts of engine running problems as we try and make the carb work again. Unusually, it looks like the passenger will be able to sit lower than the rider. Or at least have a comfier seat.
Secondly, the handlebars are a bit far away and there's no obvious mount for a second headstock. We can probably deal with this by using shorter handlebars and tilting them back. This means that we get more tiller effect as they are no longer in line with the steering axis, but this is ok for up to about 6" offset.
Thirdly, the tank is just not big enough, but there's no more space round it. We can probably rig up a secondary tank in our new bodywork somewhere.

So the plan is as follows:-

Buy a Suzuki Burgman 400. List UK price is <£3999
Remove all bodywork.
Use shorter more laid back handlebars, or a double top clamp.
Build some clamp on supports for footrests that go from the frame down tubes either side of the front wheel. These might be bolt on if we can find suitable mounts. The small front wheel means that even on full lock it doesn't need much width between the footrest framework.
Clothe the whole thing in bodywork that keeps us dry, provides real storage space and has a comfortable seats for two. That's it!
The complete Body Kit should be buildable for £1500

Given that we don't care about making it look like a "real Motorcycle" we should be able to make the whole thing much more aerodynamic. The end result should be a highly useable commuter with:-

400lbs wet weight
Top Speed 110mph
All in cost of £5000-6000 (Using all new parts and machine)
Kit fitting shouldn't take more than a day.

With the seat height we are stuck with, it's not going to be feasible to fully enclose the vehicle, but the engine rear suspension package looks good for a complete rework in a scratch build design.

Virtual Design

If anyone thinks the above is a good idea or has any opinion about it, feel free to develop drawings or pictures and email me at julian_bond@voidstar.com