SuzukiHayabusa.org
MEMBERS => MEMBER PROJECTS => Topic started by: trunkbuster on August 21, 2014, 01:19:56 PM
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I decided to put my friend's old frame to good use! With a little time and a part or two I hope to have a decent bike for the track :thumb:
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Photo_101010_001.jpg)
Found an '03 750 engine for $500
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Photo_100910_006-1.jpg)
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I thought it might be neat to try and gather the best parts from different years of GSXRs so I decided to start with a swing arm from an '08 Hayabusa that was meant for a later project.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Swingarm_zpsd0892e12.jpg)
Installed the subframe.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Swingarm2_zpse0559a13.jpg)
A pic of the parts pile.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Partspile_zps0e6cba28.jpg)
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I went through a few forks until I found a good set from the '04-'05 GSXR 750. I cleaned and rebuilt them. The one in this pic was the nastiest!!
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Fork_zps11f72e6c.jpg)
While the bike is still light I thought it might be a good idea to put the mount for the Shark Fin on.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Sharkfinmount_zps5eaf4a07.jpg)
What the fin will look like installed.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Sharkfin_zps8c327652.jpg)
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I found some race rubber on ebay! The front wheel is a UK size 125/80-17. The rear is a 190/55-17, both are medium compound.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Frontwheel_zps8590670f.jpg)
I've started on the wiring. I'll be adding a TRE with shift indicator, on-board lap timer, a Power Commander, and the Wego III from my Busa. Most of the stock wiring will be cut away. The front calipers in the pic are from an '03 GSXR 1000. I had to use a banjo bolt from a GS 1100 to go in the master cylinder. The switch housings on the clip-ons are from a 2000 GSXR but I had to cut the locator pins off so they'd fit the '04 GSXR bars. The levers are custom folding ones from an ebay store. I've installed All Ballz racing bearings in the wheels and an All Ballz tapered bearing kit in the steering head.
I'll be working on it little by little. I have a lot of minor fabrication to do on it in the meantime.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Frontwheelon_zpsf3550619.jpg)
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Awesome write up!
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Awesome write up!
Thanks :D
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More, more! :D
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More, more! :D
Okay, Okay :lol: I did a little more to it but I'll take some more pics once I get the electrical hardware put on. I'm missing the bolts to the battery tray, guess I'll have to see what I can find on ebay?
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I usually get these in one piece!
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Rearset_1_zps38161cc3.jpg)
Oh, well... I put the mounts on after I got it all sorted out.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Rearset_2_zpsd8223cb6.jpg)
The brake side was a little different? I noticed the master cylinder actuator rod mounts directly to the lever. I had to cut an inch off the brake hose for the new master cylinder height. I've got everything finger tight until I can sit on the bike and see where they need to be.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Rearset3_zpsd728346d.jpg)
The shifter side is on but the linkage will have to wait until I get the motor in.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Rearset4_zps4c140231.jpg)
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I started getting the parts ready for the DFL coating. So far, I've done the front and rear sprockets, both cams, the rear axle, and the rear axle spacers. After I get the back wheel on I might start taking the engine apart and DFL coat most of its internals.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/camblast_zps5f6fa499.jpg)
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I decided where I wanted the rear sets so I tightened them up. They're about 3 inches up and back from stock. The riding position is a little more cramped but I'll be able to hang off the seat further in the corners.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/rearset5_zpsdb9607c3.jpg)
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I built a bake box to cure the coated parts. The parts have to cook for an hour above 350 degrees F in order to cure. I figured a $250 box was cheaper than a $2000 oven.
I coated the wood with hi-temp header paint to smoothen the surface for the insulation.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/Bakebox1_zpsadc87e69.jpg)
Covered all the pieces with sheets of insulation tape good for up to 850 degrees of continuous heat.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/bakebox2_zps8ccb0e4b.jpg)
The finished product. I'll be using my 1500 watt curing lamp for heat. It cranks up to 600 degrees. You can't really see them clearly but there are wires hanging down from inside the top for hanging parts on.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/bakebox3_zpscb061e0a.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/bakebox4_zps64ab3786.jpg)
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Got the head porting done.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/P1010011_zpsa5182d4b.jpg)
Getting the combustion chamber area ready for the thermal barrier coating.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/P1010014_zps7a1776ec.jpg)
I got a busted headlight off ebay to use for my instrument cluster holder. I gutted it, didn't know the internals weighed so much!
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/P1010013_zpsf7f90aa0.jpg)
Here's what the bike looks like right now. A rolling chassis; wheels, brakes, and rear sets on.
(http://i635.photobucket.com/albums/uu76/trunkbuster/GSXR%20Track%20Bike/P1010009_zps7fb73cb7.jpg)