[toyosuprablue]

HEY CF!

I started this project about 6 weeks ago and after constantly google searching and ending up on this great forum and wealth of knowledge I decided it was time to join.

Bike as I came to own it:








Recap:
As you can see it was in great shape for its age and ran pretty well. It wasn't road worthy though because the brakes needed tweaking and the front forks leaked pretty bad.

The plan was to find a newer set of forks from a Honda CBR1000RR and any newer rear swingarm where I can swap it to a monoshock set up and eliminate the rear sub frame.

I was gathering a lot of my ideas from the guys at Classified Moto and from looking at other peoples project bikes on here and Pipeburn.com

The Tear Down:





Currently:

The front forks are off (I'll add some pictures soon) in addition to everything that mounts on them obvioiusy (Headlight, gauges, handlebars, etc.)



I bought a 2001 Ducati 748 SSSA after finding out that the pivot mount width was about 1 mm smaller than the stock 1982 swingarm making for a slightly less painful swap. Theres minimal clearance issues that I'm in the process of correcting now and the sprockets need only a minor adjustment to be lined up. Any suggestions on exact angle to place the shock's upper mounts would appreciated. I've been searching this topic a lot but haven't found much.

I just purchased a complete front end off a 2007 Honda CBR1000RR that should be arriving towards the end of the week and I bought the necessary bearings from All Balls Racing to go with them. I'll be using the clip ons and controls from the CBR1000RR as well.

I love hearing other peoples opinions because its definitely helpful so please tell me how I'm doing. I've had plenty of street bikes over the years but this is my first bike build so I'm sure there are things I'm over looking but I'll find those out along the way.

 

[toyosuprablue]

I only had the swing arm on quick to check for clearance issues on either side. Still need to find a pivot bolt that will work because the stock one for the '82 is too long. The tire looked like it was center maybe 1 or 2 mm off. Will that much be an issue?

 

[toyosuprablue]

Here is the SSSA compared to the stock one



And Here it is just loose on the bike:




Note: the tire isnt bolted to the SSSA in this pic. Its just sitting loose on the spindle because I bought it without the nut and haven't had time to pick one up yet.

 

[toyosuprablue]

I've heard people have a very difficult time getting this bike to run correctly with the pod filters and the stock carbs so I'm attempting to fab up an airbox that will supply air similar to the stock setup but in about half the amount of space.



Im going to put a mail slot in the lower portion of this box facing the back of the bike with a filter going across the middle. That way the air will still be turbulated and not force feed the carbs at anytime

 

[toyosuprablue]

Thanks for the kind words. My plan is to get the swing arm on the pivot mount 100% and then see where I'm at with the wheel being centered and all. I need to start one piece of the puzzle and finish it. Right now I have the fork swap, swing arm swap, airbox modification and battery relocation projects all started. When one gets me frustrated I move on to one of the others for a while.

 

[toyosuprablue]

Interesting jmartin. I ordered a four into one exhaust for this already because I bought the bike with a set of aftermarket pipes that didn't fit right. Will the carbs definitely need to be jetted to run right?

 

[toyosuprablue]

That was a quick chek down in NJ by RT 80 where I found the bike. Did you jet the carbs yourself for the pods or did you have someone do it? Im guessing you used K&N Pods

 

[toyosuprablue]

While i'm waiting for the forks to arrive I'm trying to decide what type of headlight to go with? traditional single round light? or maybe the lights off the 2011 Triumph Speed triple? That's my other bike so it would be neat if they matched from the front. Any other suggestions??

 

[toyosuprablue]

Forks arrived so i threw them on loose quick for a pic.


The 2007 CBR1000RR stem is the same diameter as the 1982 CB900F but its about a half inch shorter. I think if I shave the inside of the '07s upper triple tree I can gain about a 1/4" back without compromising its strength. The other option would be swapping the stems... Anyone know a way to get them out without damaging the threads?

 

[toyosuprablue]

Thats a really interesting idea, I actually just ordered a hydraulic press to assist with swapping the stems but if that doesnt work out i would try that next.

 

[toyosuprablue]

waiting for my hydraulic press to arrive is killing me

 

[toyosuprablue]

Got some interesting ideas for rear brake light and license plate mount. Mounting locations are limited with single sided swing arm. Will post pics later.

 

[toyosuprablue]

Hydraulic press came yesterday and I got the stems swapped out. Everything was going perfect and then the stem starting spinning inside the lower tree while I tightened the nut on the top that has the shield that lays against the upper bearing. I took it back apart to see how loose it is and I can't twist the stem by hand so its snug just not super tight. Is that ok!?

 

[toyosuprablue]

The press is good for 12 tons so it had no problem with the stem swap. Im alittle annoyed at how beat up it got during the shipping though so I'm probably gonna return it if I get a chance to this week. Half the paint is missing from the hydraulic jack housing and the stand wobbles quite a bit. I'll spend a little more and get the nice one

 

[toyosuprablue]

Possible brake light and license plate mount





I think it will look good when I'm done with it. I couldnt throw the brake light under the seat because not enough clearance to the tire

 

[toyosuprablue]

Front end re-assembly. I set the tank on and mold for the seat so I can get an idea of how the final product is gonna look. I re-installed all the cables but forgot to take any pictures after I finished with the clutch cable and left side controls. Gonna start the wiring soon

 

[toyosuprablue]

Because it was snug but not tight I just held the bottom with a vise grip while I tightened the nut on top. It went on easy this way and I actually overtightened it to where the forks were hard to turn side to side so i backed it off a turn or two until it got easier and then i put the lock nut and upper triple tree on

 

[toyosuprablue]

Spring for the rear shock is on the way. Hoping to get the swing arm on by the end of next week.

 

[toyosuprablue]

Spring arrives today, in the mean time I started to get a feeling for the wiring. I tore apart the stock harness and labeled everything that needs to stay and what needs to go. As far as the safety switches what do people usually take out and what usually stays? (clutch switch, neutral switch... etc)

I also got the brake lights mounted. It definitely looks different and unique, will try to get a pic up soon

 

[toyosuprablue]