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Moving engine over a d3
Second Gear User
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October 31, 2019
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November 17, 2021 - 4:02 pm
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Hi, it’s been ages since I’ve been on here, a bad accident on my Kawasaki H2 put me out of circulation for a year or so.

I have completed most of the build of my D3 trails. It has a D7 engine. However the chain is only a mm or so away from the rear tyre. I have read about moving the engine over a bit to add clearance. My questions are, is this simply cutting of the engine mounts and welding some hybrid type into place. The second question is the exhaust, at the moment the down pipe from the cylinder is butted right up to the down tube of the frame. How is this sorted if the engine is moved over?

many thanks 


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November 17, 2021 - 4:19 pm
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Everything is a compromise with a special.

Yes, moving the mounts would involve either cutting them off and welding them back on slightly further over, or cutting just the one side off, using a spacer to shift the engine over, then welding the offcuts back on so that you could put it back to standard without further cutting/welding. 

If your exhaust is that tight to the downtube then you'll have to get that cut and shut, or remade completely.

An alternative, which can give you another mm or so, is to use a second sprocket lockwasher under the gearbox sprocket, and a similar thickness spacer shim under the rear wheel sprocket to just shift the chain over a bit. Obviously, there are limits to how far you can go with this method before yet more stuff starts to foul, but it's an option.

As is fitting a smaller section rear tyre. 

Sunny Felixstowe
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November 25, 2021 - 9:09 am
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Hi Paul,

just re-Reading this post (I’ve got a D3 trail project on the go) and especially the bit about the exhaust being hard up against the frame.  With the small bore exhaust there is usually good clearance to the frame, you don’t have a large bore pipe fitted do you? Since the exhaust port in the barrel remained the same from D5 to B175 it is possible to fit a large bore pipe to a D7 top-end.  If that has been done then converting back to small bore by removing the screw on adapter ring will give you more clearance.

on the advice from the guys at Central Wheels I opted for a 3.50 x 18” rear tyre so I’m hoping there will be sufficient clearance, it looks ok but I’m a little bit away from actually having an engine in place!


“There’s nothing new under the sun”.

Central France
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November 25, 2021 - 9:42 am
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Just a thought. If you still have to register your bike, changing the frame could make things difficult (see various posts re this). If it's already registered, you may get away with it, though an insurance company might baulk at it!

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