FZRSupport: the FZROnline Archive

My FZR400/600 streetfighter:





1990 FZR400 frame & swingarm with a TZ250 rear wheel and custom Brembo rear caliper setup. Front end is 2005 GSX-R 1000 with custom upper triple clamp, Vortex clipons and linear steering stabilizer. Motor is a mostly stock 2003 YZF 600R piece with FZR airbox and Stage 1 jetting. Uses a Micron full exhaust (wrapped) with Factory engine covers. It makes about 98 rwhp on a DynoJet Model 150 dyno. Woodcraft rearsets and an Ohlins rear shock pretty much round things out. She's about 360 lbs wet at the moment, but I'm hoping to shave a few more pounds from it here and there.

Since these photos were taken, it's gotten a set of custom adjustable triple clamps that were made to my specs by a machinist friend. It's also getting a new YZF tank and custom aluminum subframe this month. I've got an FZR/YZF 660 motor that will probably go in it later this year (which I'm hoping I can squeeze about 110hp from), but as soon as the tank & subframe are done, I'll be building another 400/600 for a friend, so that'll probably keep me busy for awhile.

That looks pant stretchingly awesome!

The bike looks unbelieveable!

Do you race it or do you plan on racing it? Seems like a lot of money and work just to ride on the street.

darrin

I've seen that bike before. Are you on the R1 Forums and is that you on the R1 next to your FZR?? Either way great example of a hybrid.

Thanks, guys. It's taken quite awhile to get it like it is now, but I've still got a few things I'd like to do with it.

Yeah, that's me on my R1 next to it at Carolina Motorsports Park in Kershaw, SC. I've also had it at most of the other east coast tracks, VIR and Roebling in particular. Both of those bikes have seen plenty of track days, but I haven't had time to race for season points in some time.

I do drop by the R1 forums from time to time (as Dyyryath, there, too). I'm an ex-motorcycle mechanic and racer who tends to ride on weekends and at track days. I build the bikes for fun in a shop behind my house these days. Right now I'm working on a 75 rwhp 650 Hawk racebike and another FZR 400/600. I'll probably document the new FZR400/600 as I go with pictures, just for the hell of it.

nice.... VERY nice, How did you mount that r6 radiator?

The radiator is mounted with two aluminum brackets at the top which bolt directly to the frame and a third that extends out from the motor on the bottom. I custom made each from raw material so they fit exactly as I intended and it works pretty well. It's every bit as solid as the stock FZR mounts were.

ABS...oh, do you mean where the seat would normally cover the tank? That's an aluminum plate that is connected to the seat pan and tail section. It lies over the hole in the tank when you put the tail section on and is contoured to fit the tank precisely with a slightly rubberized back to prevent vibration (I hate rattles).

I picked up the last of the raw aluminum I'll need to create the new subframe today, so hopefully I'll get my shop cleaned up tomorrow morning and have the subframe cut, welded up and ready for powder coating before the weekend. I'm still not quite sure how I'm going to structure it, though I have a pretty good idea. It won't follow the exact layout of the stock one since I'm trying to save weight, but it will need to support the new tank, so I've still got some refining to do on the idea before I start cutting...

Wow you really created quite a masterpiece. It would be fantastic if you documented your next builds. Also please post some photos of the 650.

Can we get some more pictures of the bike please? There is just too much talking.

Looks really good. I do prefer full fairings but yours looks great

Dyyryath wrote:The radiator is mounted with two aluminum brackets at the top which bolt directly to the frame and a third that extends out from the motor on the bottom. I custom made each from raw material so they fit exactly as I intended and it works pretty well. It's every bit as solid as the stock FZR mounts were....

Ahhh… I will have to rethink my idea, I always over engineer things. Have any assembly pictures? I just got a nutsert tool which would be perfect for the bolts going into the frame.

I'll take some pictures of the brackets this afternoon to post. In the meantime, you can make very sturdy little 'L' shaped brackets that will work nicely by cutting sections of this (choose the appropriate size):

http://www.lowes.com/lowes/lkn?action=p ... lpage=none

It's quick, strong, and cheap. Works best with a bandsaw & drill press, but a hacksaw and drill work just fine. The bottom of the frame is angled, but thick. I didn't even need inserts, I simply leveled a section of the frame a bit on the bottom, then drilled and tapped it. The aluminum there is about 1/4" thick and works fine without inserts if you do a good job putting the threads in.

The bottom bracket is bolted to the front of my motor and is basically an aluminum plate with a 1/4" aluminum rod welded to it that arches up to the bottom of the radiator (it runs between the #2 & #3 pipes. It has another small aluminum flange welded to the other end for the radiator to bolt to.

I get most of the aluminum I work with at a local industrial supplier. They'll sell scrap materials pretty cheaply and they've never lacked for anything that I need. You can also buy most anything you'd need to do brackets & such at places like Lowes, Home Depot or Tractor Supply. They just won't have the really big stuff.

I picked this stuff up to make my new subframe this week for about $40:



The plate and cylinder are both 1/4" aluminum, the flat piece is 1/2" aluminum (and about 4ft long), the square piece is 1/8" wall, box aluminum and about 6ft long. This stuff is plenty sturdy for the subframe and is easy to work with regular tools. Welding it can be a trick with anything less than a 220 volt MIG, but it's not too bad, either.

Slow but steady progress. The new side plates are designed and cut. They will connect the middle tube to the frame on each side. Tomorrow I'll make the shock mount assembly that will get welded to the center of the new tube.

Great looking bike, what seat unit have you used?

I was gonna ask exactly the same - what's the seat unit from?