HOW-TO: YZF600R Swingarm Conversion Write-Up <Updated>

[mszilves]

So, what would you say on a scale of 1-10? 10 being difficult - 1 being easy

How much did it cost you mark? Total.

Not too bad at all, I'd say probably 4-5 out of 10, with most of the effort in making sure that the swingarm and dogbone pivots are ground down evenly and to proper clearance. I chose to use the stock FZR suspension knuckle, so I had to shave off about 2mm from each side of the dogbone pivot tube. The good part here is that the dogbone pivot tube bearings (the one on the bottom that connects the dogbones) do not have a lip on the inside of the tube, so you can use a proper size socket to drive them in the required 2-3mm, and then shave off the pivot tube, if you decide to use the stock FZR knuckle. This will save some $ since these bearings are not cheap. I would recommend using the FZR knuckle since if you use the YZF knuckle, it will alter the suspension ratio even more, requiring a new lighter spring. (The stock YZF spring is around 480lb/in, which is a substantial difference). My swingarm pivots were already shaved down, but just needed an adjustment, so not too much effort there, but again, if you take your time, it's not difficult either. I used an angle grinder and then finished with a file to make it square.

Everything else is pretty much bolt on, sprockets etc. some washers to space out the rearsets, 5lb sledge to finesse the heal guards. I do have a chain tool so that may add cost if you don't. I spent $270 for swingarm/wheel and various bolts etc., $70 for new DID 520 VM X-Ring (http://cgi.ebay.com/ebaymotors/_Motorcy ... 06.c0.m245) which is a steal, since it's around $120 retail, $50 total for front and rear sprockets. So in total, after all said and done and shipping etc, I put in about $400 total, well worth it IMO.

[PIMPMYFZR]

So, what would you say on a scale of 1-10? 10 being difficult - 1 being easy

How much did it cost you mark? Total.

Being that i have never taken apart a frame or anything off a motorcycle before other then the body work and mirrors i would say its a 3-4 .. now i can break the rear end of the bike down in 10 min , body , exhuast , rear sets , wheel , shock , swingarm .. but hey it took me a couple hours the first time just to get everything right ..

my cost was ..
85 for swingarm w/wheel hugger
40 for rim
60 for the tire
45 for rear sprocket
30 for front
65 for chain
40 for <2> swingarm bearings
40 for <2> axle wheel collars
20 for metrik socket and wrench combo up to 22mm
15 for spray can paint
about 30 in misc. stuff here and there
so almost 450-500 and my inital projected cost wasnt togo over 300 for everything .
but the after RESULTS for it all seeing it mounted .. PRICELESSSSSSSSSSSS
...also i woulda paid double just not to hear the WIFE bitch n moan about that damn bike gettin more attention and gifts then her..
still have to tell her she walk around with a 30K rock on her finger that my bike is so damn jealous of...lmao

[haro504]

which part the pics or the cost it seems like its about 500 for every one give or take

[PIMPMYFZR]

one thing i dont get is . if i put the yzf dogbones which are longer will it lower the bike ?

[mszilves]

one thing i dont get is . if i put the yzf dogbones which are longer will it lower the bike ?

Yes. Longer dogbones will lower the bike. Is it too tall for you now with the FZR dogbones? I'm just curious, since the placement of the dogbone pivot tube on the YZF swingarm in combination with the FZR dogbones and knuckle already lower the bike some 1/2". How much longer are the YZF bones? I measured the relative locations of the suspension points and did some quick geometry sketches, see below. (It's crude, but pretty accurate.)

Now this is eyeballing the best I could with a tape measure, but it's pretty close, and just confirms the fact that the YZF swinger in combination with the FZR dogbones/knuckle, does in fact lower the bike, the equivalent of someone making the stock dogbones about 5-10 mm longer.

From the pic below, we can see that in order for both before and after suspensions to be the same height, we need x' (YZF) to be ~191mm while x (FZR) needs to be 201mm. (These are not absolute lengths, but it's the ratios here that are important.) Of course, since we are using the same stock dogbone for x' as we are for x, we can see that in fact, we have 201-191mm=10mm more at x', which lowers the suspension by about 1/2" or so.

[PIMPMYFZR]

i can just about flat foot my bike while sittin on it before it wasnt that easy ... so in order to raise the rear then i need shorter dogbones then what i have at stock ...

[ragedigital]

i can just about flat foot my bike while sittin on it before it wasnt that easy ... so in order to raise the rear then i need shorter dogbones then what i have at stock ...

Correct.

[mszilves]

i can just about flat foot my bike while sittin on it before it wasnt that easy ... so in order to raise the rear then i need shorter dogbones then what i have at stock ...

Yep, or grab a FOX TC with the ride-height adjustment. Not only will it be a night and day improvement over stock, but will allow you to dial in your desired height as well.

[mrfreeze5]

Wow! That looks great! Nice job! I havent been aronud much lately and dont have much tme at the moment, but I really like the idea of threading a hex bolt into the sprocket, thats a nice simple fix. The only thing I would be concerned about with that, and you probably wouldnt see a problem for several thousand miles, is the weight of the bolt unbalancing the sprocket and causing excessive bearing or seal wear on the output shaft. I realize its a small amount of weight and pretty close to center, but over a few seasons of heavey use(or less maybe) it might start to leak. I do like the simple solution though. If I can ever get my camera to work right, and find more than a few minutes online Ill get the pics of my setup uploaded too. It was a pretty simple process so long as you have a new drill bit. A dull or used one doesnt do so well on the hardened steel of the output shaft.

[mszilves]

Wow! That looks great! Nice job! I havent been aronud much lately and dont have much tme at the moment, but I really like the idea of threading a hex bolt into the sprocket, thats a nice simple fix. The only thing I would be concerned about with that, and you probably wouldnt see a problem for several thousand miles, is the weight of the bolt unbalancing the sprocket and causing excessive bearing or seal wear on the output shaft. I realize its a small amount of weight and pretty close to center, but over a few seasons of heavey use(or less maybe) it might start to leak. I do like the simple solution though. If I can ever get my camera to work right, and find more than a few minutes online Ill get the pics of my setup uploaded too. It was a pretty simple process so long as you have a new drill bit. A dull or used one doesnt do so well on the hardened steel of the output shaft.

I thought about that too, but you can always put in two, one in each hole on the sprocket. But being that the headless bolts probably only weigh a few milligrams, if that, I think that is pretty much negligible on the output shaft. I have also seen front sprockets with only a single hole drilled into them, not sure why, but this would pretty much be the same as a bolt as far as unbalanced mass goes.

I'll throw up a pic of what my final setup looks like as well.

[DonTZ125]

On the topic of the sprocket nut, it seems to me that if you used two Allen bolts in the threaded holes, you could safety-wire them such that - famous last words - "that ain't goin' no-where!"

[PIMPMYFZR]

On the topic of the sprocket nut, it seems to me that if you used two Allen bolts in the threaded holes, you could safety-wire them such that - famous last words - "that ain't goin' no-where!"

yea thats what i did aint checked on it since my' swap .. just two bolts no safety wire tho

[Aivars]

Hello! Im sorry to bother you guys and renewing this topic but i have a question. I want to swap ma old 89' swingarm with 91' swingarm. Will everything conected with rear brake will fit normally? The diameter of the largest hole in this thing (89') is to small for 91'axle. If I change that thing, will everything fit perfectly, without any other modifications? For a short time, i want to have 18" rear wheel, will everything will be ok with 91' swingarm? sorry guys for my english and for that question, but i would be very grateful if anyone could answer me in simple language

[jax]

You should be able to take everything from your 89 and use it on the 91 swingarm and it will all bolt right up.

[Aivars]

The axle is longer and thicker in '91 than in '89, and that thing that holds the brake cliper- the hole for the axle is to small. Ill try to mount it, thank you for your reply