2002 R6 Swingarm Swap

[CrazyIvan]

2002 R6 swingarm swap for my '89 400 frame and '97 600 motor

Bought an R6 rear end, swingarm, wheel, brakes, and sprocket for dirt cheap.... here are picks of the process


getting ready for the 2002 R6 swing arm and wheel swap

180mm sticky tire

pulled the old wheel off

Stock FZR swing arm gone with some slots cut away for the new swing arm to slide in

made a bracket to measure where the frame used to be and started cutting away for the wider R6 Swing arm

Perfectly straight chain with the new offset sprocket

the offset sprocket i got at a salvage yard


making the rear shock mount

almost finished rear shock mount

Finished rear shock mount

had to extend the clutch actuating rod



welding in the shock mount

shock mount welded in


spaced sprocket cover/clutch

swingarm and wheel bolted in

relocated the battery to the way back, used to be right where the new shock mount is

DONE!!!!

[megaloxana]

wow nice work Mind snapping a few pictures of the bike from the side?

[cad600]

That is sweet. Man I wish I had a welder and could weld half way decent. Good work and watch out for the lower left rearset bolt. You might need to shave it down so the chain doesn't rub.

[abs929cbrrr]

good pics but we need info. please list all the info i PM'd you about so others can do this if the choose. some of us do not know how long this swingarm is or if it needs machined down to fit in the fzr frame.

besides that it looks good and i may try this since i have everything 99-02 r6 on my bike but the swingarm.

[CrazyIvan]

Here are the side pics and more specific info.



The R6 Swingarm is longer, mine is about 22.75" from the swingarm pivot to the rear axle (this is tensioned, so its almost as far back as the wheel can go, about .25" left) and the min. adjusted spot is at 21" from pivot to slot. The total wheelbase comes out to 56" which isn't too bad, still turns really well.

I did not have to mod anything on the swingarm. i made a point to only grind away a the frame because this eliminates another source of error. The 400/600 mounting width is 8.75", and the R6 is 10. When you are doing this be careful because the 99-02 R6 swingarm is not symmetric, it is a bit wider at the chain side than the right. I took, off 0.625" off the right side because that is where it centered it, and then i cut away untill the chain side fit about (0.635") ". Also, after grinding down the frame, the pivot bolt for the R6 swingarm is (20mm diameter) much wider than the FZR one, so to make it fit i just went and bought a $24 20mm drill bit and drilled out the pivot holes on the frame so that i could use the R6 bolt and bearings.

Then the chain was another big problem, instead of making a new sprocket, i went to a salvage yard and found one in a big pile, looks like it might be off a quad or something no idea. it has a .25" offset, which was enough for this. i simply flipped the nut that held the stock sprocket and put some locktite on it to give it the most surface contact with the threads. after this the chain was hitting the clutch on the sprocket cover, so i went and bout .25" spacers and spaced the plate out as well as welded on a .25" extension on the clutch rod so it would reach.

Then the next difficult part was the shock mount, and that is something i didn't measure i propped up the wheel to where i wanted it to be when it was on the ground, and sized up a bracket to make it work, if you guy's need i could make a detailed drawing of it, its pretty nice because the placement was wedged in as far forward as the bottom of the top rail on the subframe would allow, so it would be really easy to make the same one and mount in the exact same place, assuming you have the stock FZR subframe.

there hope that helps a bit. let me know if you guys want anythign else specific.

[abs929cbrrr]

sounds like you uses the stock 530 chain..520 would clear

did the r6 arm have dust caps, i didnt read anything about this. are your dimension with dust caps on or with out?

also where is your orginal shock mount vs. the one you made? this could throw alot of builders off if using different subframe such as me 636 on 400 frame.

[CrazyIvan]

its actually the 532 chain thats on here, so you might actually be fine without spacing the things out on a 520.

and yeah my swing arm only had one dust cap, so i tossed that one and the measurements are without, but they dust caps are only like .125" so its not much ore cutting

and my shock mount is sitting aproximatly 5" higher than the stock one you can kind of see the remaining parts of the stock one just below the top of the coil

[PIMPMYFZR]

first of all mad props to you because on the other forum i recall ppl saying you couldnt use this swingarm .. Nice Work
and are you far from Detroit .. so i can bring u my bike wit the same setup and you can do the same thing for me .. for a fair price or trade ..lolol LOL2

[sweekster]

Hard to believe this is the same bike you brought home in pieces hanging out of the trunk of your car. Nice work.

[CrazyIvan]

first of all mad props to you because on the other forum i recall ppl saying you couldnt use this swingarm .. Nice Work
and are you far from Detroit .. so i can bring u my bike wit the same setup and you can do the same thing for me .. for a fair price or trade ..lolol LOL2

haha thanks man, i would be down to help but unfortunately i'm down in Boulder CO, but if you do need something fabbed up i could probably do it for you, i can make you a similar bracket and put 4 bolt holes in it so that you could just drill 4 in your subframe and bolt it on without having to weld, it would hold just as well because it mounts from the bottom so the frame does all the up and down holding, the bolts would just keep it from sliding. or if you ever need anything milled from a block of aluminum i have access to the university machine shop and could do it for a fair price, i've made a bunch of custom shit for the audi there.

Hard to believe this is the same bike you brought home in pieces hanging out of the trunk of your car. Nice work.

haha thanks man definitely put lots of time into it, and sometimes i can't really belive it myself that it all came from this

[PIMPMYFZR]

boulder CO wtf you doing all the way over there hehe... im so frustrated that i cant wrench like that or else id be doing a 300mm wide tire conversion on my fzr <jk> but on a real note i keep looking at this post and makes me envious < how come he has all the skills , tools and i dont

nice audi ..my good friend has a S4 wit all the goodies , K04 turbos, down pipes .ect..ect. sick ride but the motors blown
i want a RS6 just as bad as i want a Duc 999 . but reality settles in and i get over it
theres just somthing about this car makes me tingle

[abs929cbrrr]

if you cant wrench get someone to to just modify things for you so you can bolt stuff on.

i could do alot more but i dont own the correct tools and i wont spend thousands for them. how ever i have a buddy with a full machine shop so i drop by every now and then and say hey i need this done...i trade some parts ever now and then and it buys me as much mods as i want if they are not more then about 2-3 hours a shot.

[CrazyIvan]

nice yeah, i use the university machine shop all the time to the max, its really nice we have a CNC mill, regular mills, lathes, drill press, band saws etc etc, the way i see it, there is nothing that can't be done with a bit of fab work.

[yamaha_george]

hi,
Any one in the UK who wants to do this Mod, I listed in the for sale section an Ebay link to a complete rear end for an R6 Injection modell

[95FZR600]

Made my decision. This is the swap Im doing. I have been pondering the different swaps and you have convinced me for sure. Thanks! Im sure I will have plenty of questions for you. I will be ordering a little at a time since I just picked up a 95 Suzuki Intruder with a piston problem for $300.