We got a little side tracked trying to get the Daytona ready for the bike show. I know you guys like pictures, so I figured I'd toss a couple of them up with some of the work I've done.
Okay so... this is the bike one of my racers is going to be riding this season, it's a 2005 Daytona 675 that's being "rented" from one of the local shops. It's been a race bike since inception so you can probably tell it's pretty shit kicked (race bikes get crashed a lot!). We had to literally take the whole bike apart and file any spacer/replace most of the nuts and bolts. To say it was a lot of work would be an understatement.
All said and done I'm pretty sure we've knocked about 50lbs off the dry weight of the bike... while it's wet. Does that make sense?
That's FASK. He's one of my racers, and my main motivation to show up weekend after weekend to work on bikes. He also lets me keep my projects there, but he gets a free pit crew out of it. I'll let you decide whose getting the better deal.
Obviously not fully back together.
Yadda yadda.
Finished product.
Okay, so I've actually done work. What you'll see here are the upper and lower triple to a 2005 ZX6RR. And yes I mean RR. You'll noted that the upper has the ignition loop removed. I'll still need to clean it up for street use.
I had FASK who is a journeyman machinist and currently working as an elevator mechanic call in a favor and get a couple of spacers made up for me.
I installed them by myself with a hammer and some moly. The nice thing about living in Canada is that you don't need a freezer to shrink parts. Mothernature provides that for free. They were both measured to a 1 thou interference fit (his knick name is 1/10th Spence for 1/10000 of an inch). It actually worked out really well.
I used the following tools:
Snow
Large rubber mallet
Propane torch
Moly grease 1%
Delray frame slider
Large ball-peen hammer
Leather work gloves
20mm deep socket
The lower bushing was quite... ingeniously designed in that it has a small step on the inside that allows the FZR steering stem to be installed at the stock height on the regular steel triple as opposed to the ZX6R which is much taller. The inner diameter was set as an exact fit to take into account the compression of the 1/1000th interference fit (you cannot buy that kind of knowledge). Also the leading edge has a taper to aid installation. FASK you do amazing work!
Anyways, I tossed the spacers in the snow and heated the lower triple till I could barely touch it with my leather gloves on. Then spread some moly grease on the spacer and hammered it into place, it takes a keen eye and a decent amount of rapid hammering to get it into place. I got it to work, don't worry.
Tossed the triple in the snow to cool it and then prepared to install the steering stem. The same process was repeated, but I used the socket to pound the stem into the hole with a little moly grease to ease the passage.
The upper spacer has a lip to take up the difference in the height of the upper triple which will be run inverted.
The bearings themselves were cleaned and reinstalled by using the delray slider a hammer a brute force to reinstall. I packed them with Mobilith SHC 460 grease. Which is a high quality synthetic suitable for low speed heavy load applications where water washing is an issue. It's not something you would use for say a wheelbearing, but considering the speed at which your headstock moves it's just about perfect.
Now I need to remove everything and paint it, but at least I know it works haha.
All of this would be much easier with access to a machine shop, but there's something about doing it the old fashioned way that seems to fit with the general project theme.
Wait until you see what we do with the frame!