99-02 R6 wheel swap for 95-07 YZF600r swingarm

[abs929cbrrr]

ok so here is my write up on the R6 wheel swap.
If you got the money do this, do it! (a ruff idea of cost is what i paied for my parts)
YZF600R swingarm with shock and everything ($95)
R6 rim with after marke waved bracking rotor ($150)
R6 super sprox tri metal sprocket ($90)
R6 brake stay with new pads ($45)
axle sleeves ($90)
machine work (free because i got connections)

total hours for the swap maybe 30 mins to 1 hour if your follow my instructions. If you choose not to follow my instructions then figure 8-12 hours of figuring out dimensions and materital tolerances. (trust me i am mechanical drafter so just follow the little sketch)

it's so simple is not even funny because i already figured it out for you (about 12 hours of thinking and messing up)

1st buy a YZF600R swingarm 1995-2007 (all the same)must have the yzf600r alxe also.
2nd buy a R6 rim 1999-2002 (all the same) and the sprocket hub stuff and all the rear brake stuff.
3rd follow my 1st post about cutting the YZF600r swingarm to fit you your FZR400/600 frame
4th have modking or someone else (modking already has the tools to make these parts) machine these spacers/wheel sleeves. the R6 axle is like 1" dia larger then the YZF600r so you need these made from 6061 or 7075 aluminum (warning they will not be cheap)
here is the drawing and here is what they look like. ****Just realize the left side sleeve has to have a dimension of .440 not .500 (i already messed up and had to have mine remachined down)****. every other dimension on there is correct. i didnt feel like redrawing the drawing and taking a picture. (the R6 wheel hub is not centered so it was a 6 hour pain in my ass to figure this out)


5th install the spacers left and right into the R6 wheel, but grease them 1st...do i really need a pic for this?!?!?!?
6th have somone cut a 1.50" long peice of bar stock (steel) and put your wheel in the swingam as close as it can go in the chain adjustment slot as shown and weld the bar paralell with the swingarm (refferance dimension it was about .500-.600" high) drill and tap the bar 1st 1.25" deep for a 8mm bolt and then tightening everything up so you can tack weld it in place.

7th remove everything off the swingarm and weld around the entire peice of bar stock as shown

8th cut off the orginal yzf600r brake stay mount, you wont every need it now. all the other mounts are the stock hugger mounting tabs so keep them.

9th test fit, put on bike, paint or do what ever you want. i dont think i need to show you a pic to do this haha.

[megaloxana]

Great write up abs. Glad you're giving back to the community from everything you're learning as you build your awesomeness of a bike. Having a drafting background myself, I can really appreciate the dimension sketch.

Great Job

[mrfreeze5]

Very Very cool ABS!! I may look into this a bit later down the road. That would give me a perfect match to my front R1 3 spoke wheel and would give me a good brake upgrade. How is the sprocket alignment?? Do you have a weight for the wheel?

[abs929cbrrr]

i was told from a member sprocket alingment is the same as the yzf600r. if you use the yzf motor its not a problem, if you dont you need a 636 front sprocket to shim it out.

weight of the rim is lighter then the fzr600 wheel so i think it would be lighter then the yzf600r too since they were heavey cast wheels.

[PIMPMYFZR]

so you did this so u can use the r6 wheel or r6 brake ? im referring to the barstock brake mount . Could u not have used the yzf brake mount wit the r6 wheel? i only ask because i just picked up a yzf swingarm and pondering if i should get yzf wheel or r6 i want to put a 190 on there

[abs929cbrrr]

you cant use the YZF600 stuff, its to large, also why would you want to use it anyway? get R6 stuff follow the post. also dont run a 190 on a rim ment for a 180. trust me a 180 is very huge for a fzr.

The yzf stuff is designed totaly different meaning the spacers i deigned to be used would have to be redesigned to use older style break components. i did this because i wanted a R6 wheel, i hate the YZF set up and style. also the stupid YZF break touque bar prob would of been to close not alowring me to run a 5.5" rim. R6 rims are cheaper then YZF parts also, ebay is littered with old R6 stuff....just try and find YZF stuff cheap now.

[abs929cbrrr]

NEW info on this:

when mounting this into a FZR400 or FZR600 your sprockets wont aling right. the rear is around .20-.25 off (what ever the thickness of a 520 pitch sprocket is it is off by that much) This is already using a 520 pitch offset 03-06 zx6r front sprocket. If you use this sprocket and a YZF600r motor you should'nt have a problem lineing this up.

what you need to do to fix this is if you are using a 400 or a 600 motor is machine the rear sprocket hub of the 99-02 R6 down the thickness of the sprocket. the studs have to be removed 1st, machine it down and then just retap the holes to get the burrs off.

I will be doing this tonight, its the smiplest wasy to keep the rear wheel still centered in the yzf600r swingarm.

[abs929cbrrr]

some one pin this thing up for others to do.

[mrfreeze5]

ABS, you think your buddy would make up some of those spacers for the axle?

I'd be up for a set too.

[mrfreeze5]

Youre running a FZR600 engine, 636 520 sprocket right? Thats the same as what I have. Exactly how much did you machine down your sprocket hub to align? Im starting to source parts for this swap now.

[abs929cbrrr]

my buddy didnt make the spacers...i got modking to make them. he had them done and shipped to me in a week so just as him. make sure you use the right dimensions on the left side one since at 1st i was 1/16" off. i listed the correct dimension on the 1st page.

i machined the sprocket hub doen .22. you have to use a torch to head up the studs since they are threaded in and have loctite on them.

mod king charged me $90 shipped for spacers. after 200 miles everythings working like i designed.

[abs929cbrrr]

no prob. you'll love it and with your tail swap it will looke lika r6 then. any questions just ask me since all the info is in my head haha.

[abs929cbrrr]

some one please make this a sticky so i dont have to PM everyone on how to do it. this is sticky worth since i was the 1st to do it and it worked!

STICKY ME PLEASE

[abs929cbrrr]

no pics, its as simple as guying the front end you want. (go with a 3 sproke wheel, 5-6 spokes are bitches to clean) just have the stem pressed out of your fzr tripples into the forks of your choice. i personaly would go old R6 or R1 if i did it again. 636 shit is just too over priced.

[shredex]

I can have these spacers made (i have a good friend that does great work with his two metal lathes and milling machine).
if anyones interested pm me.