Project Freestyle

[Freestyle72]

So I am putting a hybrid together. I am going to streetfighter it because frankly I am not interested in all the attention the police like to show full faired bikes around here. Everyone around here considers anything without fairings to be basically a cruiser so that's what I am doing.

So here's what I am doing so far.


So that's

-05 GSXR600 forks in 06 GSXR1000 triples with with GSXR1000 calipers, axel, controls, etc
- yzf600 gas tank
- 03 GSXR Alstare rear wheel
- 96 SRAD GSXR750 swingarm
- 07 R6 subframe and seats (Still looking for plastics)
- 06 GSXR1000 front wheel

I am starting with this




Now she's naked.

Gunna put the fairings back on just to get her to pass safety and then I am gunna start tidying her up. I think I am going to put the GSXR front end on first. Then the swing arm later. It has a 4.5" TZ250 rear wheel right now, which is going to be for sale soon as I get it off the bike.


I am going to the machine shop later this week to talk to them about making me an aluminum shockmount that will let me bolt my R6 subframe to.

[mrfreeze5]

Oooo, Im liking the looks of this one Keep us updated. Lots of pics!

[ragedigital]

I love Hybrids... but, you should be beaten in public. That FZR400 is in incredible condition and could fetch some coin.

I destroyed a nice 600, so I understand.... a little. I just know that the 400s in that condition are becoming extremely rare.

darrin

[Freestyle72]

Well the way I see it I am not really destroying the 400. All the things I am doing require no alteration to the frame etc. So it could potentially go back to stock 100% later. However I think my interpretation of the FZR400 could be more fun. Especially with the 683cc beast on there

[Model192]

noo dont kill the 400 and it's fairings it's too clean

400cc on some old school fairings will fetch SO much more cool points in -any- motorcycle circle than any generic naked streetfighter

[Freestyle72]

noo dont kill the 400 and it's fairings it's too clean

400cc on some old school fairings will fetch SO much more cool points in -any- motorcycle circle than any generic naked streetfighter

Oh I totally forgot I was going for cool points, instead of having a bike that makes me happy. Thanks for putting things in perspective for me.

I'll sell you the complete fairing set and you can fetch all the cool points yourself.

[mrfreeze5]

noo dont kill the 400 and it's fairings it's too clean

400cc on some old school fairings will fetch SO much more cool points in -any- motorcycle circle than any generic naked streetfighter

Oh I totally forgot I was going for cool points, instead of having a bike that makes me happy. Thanks for putting things in perspective for me.

I'll sell you the complete fairing set and you can fetch all the cool points yourself.

Well, at least youve got the right attitude for building a fighter

Personally, I would have loved to have been able to start with a clean bike in good shape. Most fighters are cobbled together from whats laying around and look it. This one has potential.

[Target30]

you can send me the fairing set if you would like! i'll even pay for shipping!

[Freestyle72]

Any suggestions on how to strip the tank? Seems like there is bedliner or something on there right now. Any idea what chemical to use to strop that? Or should I take a wire wheel to it?

[thatkid]

kleen strip will do it. Or use one of those scotch brite paint strippers that attaches to a drill.

[sweekster]

Any suggestions on how to strip the tank? Seems like there is bedliner or something on there right now. Any idea what chemical to use to strop that? Or should I take a wire wheel to it?

You don't want it to dry out because the paint will be a lot harder to get off.

[Freestyle72]

Thanks guys I'll look for that tommorow.

Went to get the bike safetied (ministry inspection) and my rear brakelight switch and plate light were out. So I put in a brake pressure switch. Way cooler then the regular mechanical switches and works with any rearset which is good.

Gunna pick it up from the mechanic tommorow because he couldn't get to safetying it today. So tommorow I am taking it to the welder/machine shop and I am going to discuss a custom aluminum shockmount/subframe connection. Going to try to get rid of the steel subframe and have something for the r6 to mount to at the same time.

The swingarm I can almost do the whole job my self I just need the machinist to bore out the GSXR pivot axel to accept FZR one inside it. And I will also ask about pressing the stem, welding around it then having it turned down.

[Freestyle72]

So looks like I am going the custom bearings route. I sent an e-mail to Zoran at TWFracing. He makes a bearing that is 30X47X15. He makes them for the old gen SVs to fit GSXR forks, but the FZR will need the same bearing size to accept the GSXR stem. Another thing this does for me is I can put a spacer either at the top or the bottom of the GSXR stem as I believe it is longer than the FZR. Now here is the thing I will place the spacer at the bottom because that will buy me more fork length. The GSXR fork free length is 725mm by my measurement. Someone on this forums posted the FZR forks are 790mm fork free length. Now to keep steering geometry similar you want this length to be the same you can adjust your sag and stuff like that correctly.


The difference is 790-725= 65mm

We have about 30mm from the FZR clip ons being on top of the triple and the gsxrs being on the bottom. And then we have (120X0.70 - 110X0.60 = 15.6) 15.6mm from using 70 profile tire. So that puts me at 45.6 mm. And I still need to make up 20mm. So depending on how much longer the GSXR stem is than the FZR that should help make some of the distance up for me. I know people like to raise the forks in the triple a bit to improve handling for the FZR so I am just going to pretend like I did that and In my mind the distance is made up for. I was thinking about getting forkcap extenders as final option but I don't really want it to come to that.

[Freestyle72]

Started on the swing arm swap today. Barely going to have to cut anything off the GSXR swing arm. Although I might say that it was a bit of a whore getting the fzr swingarm out. I also weighed some parts and was very surprised with the weights.

FZR400 swing arm with brake caliper etc 6KG or 13.2 lbs <--- the GSXR swinger is 22lbs so I am gaining about 9 lbs there. I might try the SRAD 600 arm later for a lighter weight option in the future.

Fox shock 3.6kg or 7.92 lbs

TZ 250 rear wheel 14.2 kg with tire, cush, sprocket or 31.2 lbs <--- the GSXR 5.5" wheel is only slightly heavier by like a pound or something which isn't bad at all.

Sitting naked


Getting her up on stands


GSXR Wheel vs TZ250 wheel



Wheel off


Shock off


Swing arm off and sitting by the new swinger


Two fizzers and the ninja



Test fit GSXR swinger


Mock up


Look how freaken tiny the FZR pivot bolt is. Going to look into brass spacer to get it to fit inside the GSXR bolt



Sits inside gsxr pivot bolt with room to spare


So on my list of things to do is pull the bearings, and have brass sleeves made for the FZR pivot bolt. And then cut down the bearing spacer in the swingarm and then cut the swingarm down by the same same amount to get it to fit the frame rails. I estimate about 6-8mm total of cutting.

[Freestyle72]

Been hustling all day to get this done. Only thing left needed to bolt it all up is I need a sleeve made for the stock axel. It has to be 15mm ID 25mm OD and 217mm long. If any machinist is reading this shoot me an offer on how much an aluminum or bronze sleeve would be.



Bearing puller I grab from the U S and A





Worked great got the bearings out

Then I tossed the bearings into the freezer



Chopped the swingarm down to the size of the frame. I removed 5mm from each size and tossed the spacer inside the dust covers. 222mm just like the FZR frame





This is the spacer inside the swingarm that keeps the inner bearing races from falling inside the swingarm. Cut it down by 4mm on each side and test fit with the races to make sure it was all good.





Put one of the bearings and inner races back in. Saving the other side to take to a machinist in case they need it. It's also in the freezer right now with the bearing.


Trimming rearset area



Sucks no machining can get done tommorow because then I could bolt it all back together and go ride it! Actually not really. I still have to confirm sprocket aligment. And then swap the sprocket out with a -1 ninja sprocket I have to regain alignment which I suspect I will have to. And then I have to get and rivet a chain, which will be the easy part. I have inhaled for than enough aluminum dust today.



But the hard part is done. Everything should be bolt on from here on out. And that includes the rest of the mods. Even the subframe, I intend on mocking the brackets up on cardboard and taking it to the shop and have them make it in aluminum. Can't wait to be done though. It's depressing to have such a warm day out but have no bike.



Picked up my GSXR front wheel today as well.