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Hack in a barn
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4,409 Posts
Discussion Starter #1
Ok so I sold my drz400sm which was a second bike to the one in my avitar. I did love the supermoto but I wanted to get into something more of a project, so I picked up a crashed 2000 R6 off a friend of mine and will be using the money I got from the drz to build a streetfighter out of it. Here it is when I picked it up and rolled it off my truck.





So I've been messing around with it just to get it fired up and make sure it runs, which it does :party-smiley:
So now I'm trying to get the bike some what together enough to take it for a super sketchy ride down the road to see if the transmission is ok.

Part of that was reinforcing the top triple clamp for the dirt bars. One of the previous owners, not my friend I got it from but a guy that we know, had already drilled the clamp so I have to finish it up. With the holes being close to cast in reinforcement that ment to get a nut on the riser bolts I'd have to either grind some of it out or fill the void in the clamp. With it being a pretty thin piece of aluminum I figure filling it and having a solid plate under it would be the safest option.





After a little time with the dremel I got the voids I need to fill cleaned up and ready for some spackle.



I used some PC-7 two part goo. I was going to go JB weld but you don't get a whole lot in the tube so I went with this stuff instead, same concept as JB.



Here it is all filled in.



I've got a few cool parts coming in and will get to some hopefully neat looking mods, but I need to get the small B.S. out of the way so stay tuned it will get better....PS I'm a solid pic whore, so I hope y'all like pics...
 

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Hack in a barn
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4,409 Posts
Discussion Starter #2
This is the tank that came with the bike, dented on the outside and rusted on the inside.





So I found one on ebay with no dents and just a few scratches and a spotless inside at a good price so I picked it up. The best part is that it's the yamaha blue that I wanted :D ...



 

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Good start. I too, am in the works of starting a fighter build on a 1st gen R6 (2001). Will be watching this one in interest, keep up the work!
 

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Hack in a barn
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4,409 Posts
Discussion Starter #6
I got the seat I'm going to use today, it's off of a ducati monster. I know you guys have seen it a bunch of times and so yeah it lacks in creativity, but these seats just plain look good so it is what it is :D. More than likely I will end up making my own subframe to mount the seat in the end. The last pic is with the fiberglass seat cowl installed. I'm pretty psyched about it, once it's sitting down on a subframe I think it will look good and be pretty darn comfortable too.








And thank you to the early subscribers too! Y'all are in it for the long haul on this one...:lol:
 

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Hack in a barn
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4,409 Posts
Discussion Starter #7
Well I'm happy to report that I took the bike for a super sketchy shake down ride today, and everything in the tranny and motor is good! 99% sure the forks are bent though, but thats not a huge problem. Atleast now I can start on the fun stuff and not have to worry about the drivetrain...
 

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Hack in a barn
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4,409 Posts
Discussion Starter #8
Well I got a second generation r6 swingarm, linkage, shock, axle and brakes in today, after seeing the bikes "jarrad" and chulada" built I decided that it would be a good choice.



Gave her the old familiar come along from the ceiling and home made rear stands treatment to pull the front forks off and assess the damage on them. I'm not 100% giving up on the conventional forks for this bike, honestly they are a good fork, I may just have to buy another set. If I could come across the right inverted front for the right price I may go that route though.



I have the forks on the bench ready to be disassembled and inspected, that will be for tomorrow night though.
 

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Hack in a barn
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4,409 Posts
Discussion Starter #9
Got to do a little bit of work on the swingarm today. I have it loosely fitted to the bike at this point, just trying to work out how the new shock and linkages would change things.

I picked up the pivot bushing and washers off of a 2nd generation to use, although the pivot bolt is the same, the 2nd gen. has a smaller diameter bearing on one side of the pivot, while the 1st gen. has the same on both sides. Therefor my old pivot bushing won't work. Also the thrust washers are different so I needed the newer style of those. That should be here soon.

Some of the differences between the two are as follows. Pivot width is shorter in the 2nd gen. vs. the 1st gen so I will have to make up a couple of spacers to get everything on center. With the bolt being the same it is just a matter of spacers and the pivot will be taken care of. The width of the swingarms at the ends are different too, the 2nd gen. is about 9.5" and the 1st gen. is about 9-13/16, but the brake caliper bracket is also different on the two. The caliper bracket on the 2nd gen. is about .850" and the 1st gen. is about 1.170", so in the end the width that the wheel has to fill is 8.65" on the 2nd gen. and 8.6425 on the 1st gen. Close enough for this hack. Also the axle diameter is the same so I'll use the 2nd gen. axle on the 1st gen. wheel.

My 2nd gen. shock is 11-3/4" eye to eye and the 1st gen. is 12" eye to eye, with the dog bone on the 2nd gen. at 7-1/4" eye to eye and the 1st. gen. 7-5/8". The linkages are also different but when the two are mounted to the bike my ride height (measured from a point on subframe to middle of axle hole) is at 22-3/4" with 1st gen. and 24" with the 2nd gen. So right out of the box it will be a little taller. The length from pivot center to center of axle hole is 22-1/2" first gen. and 23" on the 2nd gen. so it's a little longer with the newer style.

The weight is ~25 pounds for the 1st gen. and ~22 pounds for the 2nd gen. That is with shock, all linkages and chain. So it's a little bit lighter. :rock:

It worked out that the eye width is the same on the two. So it mounts to the top mount on the bike no issues. Just had to take the bracket off the top of the new one.





The dog bone isn't as wide on the 2nd gen. where is mounts to the bike, so I will need to make a couple of spacers for that and it will be squared away.



All the new linkages bolted up no issues.



Here is how it's looking so far. I'm loving the way it looks with the frame of the bike!





Sorry for the longish post if you are still reading but I want someone to look at this thread and know exactly what they would be up against if they went this route, rather than ok here is a before and after picture for you.
 

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Hack in a barn
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4,409 Posts
Discussion Starter #11
lookin good mate!

the Gen2 swinger makes all the differance, i like the tail ur putting on it too
makes me miss my R6...

R1 forks????
Thanks very much, your bike was one of the ones that made me pull the trigger on that swinger! I have the pic of it outside when you got in on there as my wall paper for insperation lol...

Well the front, funny you should ask. I forgot to mention that I did get the forks torn apart and my right is bent and my calipers are rusted junk. I'm trying to stick to a budget so I'm probably going to stick with the stock forks.

But... If I can find a buell XB inverted with the perimeter mount brake for a good enough price that would be my choice for frontend just because it is something unique. I doubt that I could lol but that would be the inverted choice over stockers.

 

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Hack in a barn
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4,409 Posts
Discussion Starter #13
The 03-05 swingarm bushings and thrust washers that I needed came in so I threw them into the swingarm.



The 03-05 arm is not as wide as the 99-02 at the pivot so I needed a spacer. I measured 7/16" difference, and the old right side spacer on the 99-02 arm is 3/8 with the same diameter hole so I used that on the new swingarm.





Right now I have it on the left side, I have read that some use it on the right side with the screw in adjuster to correct chain alignment.



I threw a couple of washers in the dog bone at the motor to take up the space there.



Right now the shock is close to the front of the arm, I think when it's under it's own weight everything will be good but I'll have to check at that point.



Onto the current problems :lol: The rear brake caliper bracket is interfering with the rotor bolts BAD the axle isn't even on in that pic and the wheel is crooked. Others have machined out the caliper bracket to get around this problem. I was going to go a different route though.



My plan was to use a 98-01 R1 rear brake rotor and new style 03-up R6 rotor bolts. The R1 rotor had counter bored bolt holes and used a 6 bolt pattern like my R6 and the new style R6 bolts were nice and flat to clear the bracket.

So here is the R1 rotor with it's 6 counterbored mount holes unlike my R6 rotor that has regular holes drilled.





This is the bolt off of a 03-up R6 notice its flat and goes into the counterbore on the rotors on those bikes, I didn't use a rotor from the newer bikes because they are 5 bolt pattern and I need 6 bolt pattern. I would need to buy one more of those bolts to make it work.



BUT :lol: the rotor turned out to be too big to fit in the caliper and the flat new style bolts are larger than the old ones so I would have been stuck drilling out and taping my wheel to make them work and then counterboring my old rotor, or machining my new caliper bracket.

I chose none of the above and bought a 03-05 style R6 rear rim with rotor, sproket and spacers on it and then a 07 FZ6 front wheel with rotors and spacers. A big plus is that now the rear wheel is good to go and an even bigger plus is they are a nice looking 5 spoke wheel compared to the tried and true 3 point mags.

New wheels:



Old wheels:



With the rear wheel sitting (I think for now lol) where it needs to be I was able to mount the 03-05 rear master cylinder on my controls with not major problems. The holes were right on but I'll need to work out a mount for the reservoir later because the hose is a little shorter, no big deal.



The rear control is now hitting the swingarm but untill I figure out the final alignment on that I won't worry about it besides if I have to space out the control that won't be a huge project.



With the rear at a good point I turned my attention to the frontend.

The FZ6 wheel went on no problem, the spacers are the same as my 02 (as are the newer R6's) and the axle diameter is the same.



The problem you will encounter is the brake rotors. They are 4mm (so I've read) closer to each other than the 99-02 rotors, it's the same on the 03+ R6 too. So when the calipers are place on the rotor contacts the inside edge of the caliper.

Kinda hard to see here but it's no bueno.



Real simple solution a flat washer on the top and bottom caliper mounts and space the caliper inward. Now the rotor sits right where it needs to be.



So that is pretty much where I left off, here is a crappy inside a crowded "garage" shot of the bike to get a look at the new wheels. I'll try and get it rolled out for a outside pic tomorrow.

 

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Hack in a barn
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4,409 Posts
Discussion Starter #14
Made up a couple of spacers out of 1/8 aluminum for my right side control to get it off the swingarm.





Clearance is better now.



Then more or less threw it together to wheel it out and take some pics. Here is where I wouldn't mind some opinions, my headlight choices are 7" buell round which I do have a flyscreen for and would put it on, or a KTM 690 headlight. I really thought the 7" would be my first choice but the KTM light is making me think twice. Niether are really aimed or "on" in these pics but you can get the idea. Thoughts?...

Buell...







KTM...





 

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Hack in a barn
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4,409 Posts
Discussion Starter #16
loving the KTM light mate :)
Thank you for the input sir!

So I was with you on that, I liked the KTM light a little more so I have another fender I could use too, here are the pics. Up first is what I think is the new front runner for me, in fact %99.9 sure this is what I will use.

KTM headlight/ Buell Ulysses front fender :rock: :rock: :rock:







Buell light and flyscreen and R6 fender.







Buell light and flyscreen / Buell Ulysses front fender







Buell light no flyscreen/ Ulysses front fender





 

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Booo Yaaa!!!!
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Subscribed!!! What about KTM light with R6 fender or no fender! Love the look of the light maybe not so much the fenders though but either way it's gunna be badass
 

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KTM headlight/ Buell Ulysses front fender for a unique look!
 

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Hack in a barn
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4,409 Posts
Discussion Starter #19
Got my brake lines in, the reason I'm posting about them is because they are off the shelf FZ6 braided lines so there is no need to special order. Went on ebay and a couple of days later bam extended brake lines done. Here is a pic because I'm a whore.



Then I got around to the speedometer bracket, with space being cramped in back of the light because of the ignition I had to go somewhere else with it. I wasn't going to chop the ignition off and loose the steering lock.

Some sheet metal.



Mark and drill the holes.



Up on the clamps now.



Couple of bends.



Add a "V" cut to mimic the headlight shape.



And there you have it. Use some imagination on these pics, the bracket will black one day and the seat will sit down on the subframe one day too. But you can get the picture lol.



 
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