Starting my build

[Bike_junkie]

SO I am starting my build. I am putting a set of Showa BPF, Ohlins rear shock, 3tj swinger, and a yzf600r engine on an 88 fzr400. I have pictures but they have to wait until I am on my computer to be posted. One bit of info that I have now is the fzr4003tj rear sets that show up on ebay from time to time for the 3tj will fit the 1wg frame pretty well.

[j200pruf]

Sounds like a great build, looking forward to seeing progress pics

[tgold]

Cool, Lets see some progress pics!

I'm putting a 2003 ZX6R front end after I heard some mixed reviews about the ease of tuning the BPF forks. Regardless of that, your fork will be a huge improvement over the stock front end. What are you doing to adapt the triple clamps? I decided to press the FZR steering stem out of the lower clamp and then machine the ZX6R stem down so all that will be left is basically an adapter collar for the FZR stem. Then I'll press the fzr stem in, and I'll be able to use the stock steering head bearings. As much as I wanted to use the nice and light aluminum ZX6R stem, I couldn't find a suitable bearing to make it work well without spending a lot of money. By the way, All Balls Racing has an excellent cross-reference chart for steering head bearings for front-end swaps on a huge amount of bikes: http://www.allballsracing.com/index.php/forkconversion

If I really feel ambitious, I may just machine a new stem out of aluminum.... I just have a hard time putting that heavy steel stem in a bike that I'm trying to finish with a target weight of 250 pounds


Another note: The stock FZR steering stem has a little retaining clip near the bottom that you can't see..... After I cut most of the lower clamp around the stem away, (leaving less than .5 mm of steel next to the stem) I figured I'd have an easy time of pressing the stem out with a hydraulic press, since the remaining part of the clamp would simply stretch a little and give way...... It probably would have if I had pressed the top of the stem down through the bottom clamp. For some odd reason I decided to press it out the opposite way, gradually increasing the force till it let go with a hell of a bang and parts flying! Fortunately I didn't hurt myself or anybody else..... Note to self: Always press the stem out of the triple by pressing on the top end of the stem!
There's a saying that we are born with a full bucket of luck and an empty bucket of experience. The trick is to fill the bucket of experience before we empty the bucket of luck. Well, I just emptied a good bit out of my luck bucket and added a little more to my experience bucket!
Best of success to you!

[Bike_junkie]

The suzuki stem is too short, so I am gettin a friend that can weld aluminum to lengthen it a bit. For the top bearing I am using a slightly larger OD bearing and opened up the neck enough for it to fit. Took me about 10 minutes to do. Right now I am waiting on boring bars so that I can make the bearing spacers for the swingarm and wheel spacers for the back.

[SouthendChris]

Isn't the best way to fit the FZR stem into the 'Showa' yokes? You can then use the std bearings for the FZR. Also in the future if you want to use the Showa front end on another bike then the FZR400 chassis/frame wont be scrap.

I fitted a 4XV 'R1' front end to my 3TJ and it wasnt the easiest job to get the stem to fit - but with shims and some alloy welding to the top yoke it went together quite well. I didnt even need to mod the frame for lockstops, although I cant use the anti-theft ignition steering lock (as if we would leave our beloved projects alone in public! ).



Chris

[Bike_junkie]

The frame has some dents and dings. I also do not have a fzr stem to adapt. So I am going with what I have, I do have a second frame thats a little better, but it needs a title.

[tgold]

Isn't the best way to fit the FZR stem into the 'Showa' yokes? You can then use the std bearings for the FZR. Also in the future if you want to use the Showa front end on another bike then the FZR400 chassis/frame wont be scrap.



Chris

Yeah, that's the conclusion that I've come to. Hopefully I'll be working on it this evening.

[thatkid]

For anyone wanting stem swaps you can send them to me and I can do them. Bike Junkie, I have extra stems if you'd like it done this way.

[Bike_junkie]

I already have it worked out to lengthen the GSXR stem, so I am going to stick with that for now. If I ever change frames I might swap stems, but not this time around. My boring bar came in today, so hopefully tomorrow I get to make the bearing spacers and wheel spacers for the back.

[Bike_junkie]

I got the 3tj arm adapted. I took the standard swingarm bushing chucked it up in an old southbend lathe and cut it down to a 20mm OD so that it was a tight slip fit in the 3tj bushing. I need to trim 10mm off of the sprocket carrier of the carrozzeria wheel to get it centered in the swingarm. Once I do that and get tires it will be up to a rolling chassis.

[Bike_junkie]

Here it is with the yzf engine dropped in.

[Bike_junkie]

Update, its sitting on its wheels now. Subframe is about half done. I have a plan for the front tank mount, just need to build it now.

[SouthendChris]

Always nice to see progress with projects. Looking very good so far

Chris

[Bike_junkie]

Waiting on a couple parts to get her, once here and installed it should be running and riding. Then I can work on the tz fairings and making it pretty.

[Bike_junkie]

So I have had the bike on the road for a few days now. The yzf carbs are fighting me with the pods. But I have it running decent. I also got lucky and picked up a factory pro shift kit for $25