Time to stop being a lazy 'arris and do something useful

[yorkie_chris]

Some Christmas presents from me, to me:
http://img695.imageshack.us/img695/9567/dscf7366.jpg
Ducati 999 rear caliper and hangar and some very nice spacers from DavieSV to make it fit. Loads lighter than stock item and anodised so it won't sieze up every 15 minutes.

http://img51.imageshack.us/img51/6311/dscf7365.jpg

Uprated front springs and full synthetic oil for forks.

http://img51.imageshack.us/img51/556/dscf7363v.jpg

Penske 8983 rear shock :thumleft:

http://img683.imageshack.us/img683/3712/dscf7364e.jpg

And revalve for forks to sort out shortcomings of them and match them to new spring.


big thanks to Zoran at twin works factory for excellent service with shock and advice

[Scoobs]

Nice.

[maviczap]

Is this for your Curvy YC?

I'd like to see this conversion done in stages if it is. Just out of interest :cool:

[yorkie_chris]

Yes it is for curvy. I will take some pics

[maviczap]

Good

[yorkie_chris]

Any particular bit? Shock is easy, fits same as stock. Caliper only hard part will be drilling swingarm I think.

[maviczap]

Just the caliper conversion, even I can swap a shock over :rolleyes:

What's the advantage of conversion. Losing the torque arm is one.

[yorkie_chris]

Main practical advantage is it is anodised. Stock is plain cast alloy and siezes very easily. Those brembos are much better.

Also these pics are comparable. They both include banjo bolt, pads in similar state of wear, torque arm and bolts. Everything needed to attach. Only thing not accounted for is the metal removed when drilling the holes in the swingarm, maybe an inch or so different brake line (not checked lines at all yet) and bit of safety wire. and these spacers could be made 25% lighter IMO.

http://img191.imageshack.us/img191/3062/dscf7369.jpg
http://img690.imageshack.us/img690/3488/dscf7367o.jpg


Ok here is step by step:

First just to verify that I am not that much retarded that I can't add up.
Slide everything that goes onto the axle onto the axle and measure thickness. This is important part because any retardedness creeping in here will change wheel alignment/chain run.
On first check they were .1mm different, but after cleaning off a small burr on the caliper hangar they are exactly same on cheapo vernier. Close enough for me.
http://img205.imageshack.us/img205/6033/dscf7370.jpg

Now just bolt up same as stock;
http://img163.imageshack.us/img163/9594/dscf7373w.jpg

Caliper seems to be aligned near enough for use. I will check to more accuracy to get caliper centered over disc but it is within .5mm or so.

http://img27.imageshack.us/img27/5303/dscf7372g.jpg


There is also hole there for speedo sensor, looks like perfect fit for honeywell GT101DC, but that is a bit too long so it will need shimming outboard.
Only thing I am worried about with this is is there space to fit magnets, or will magnets need to be recessed into disc/wheel.

http://img191.imageshack.us/img191/4337/dscf7375.jpg

[maviczap]

Yc, thats a neat conversion. I'm interested to see how and where your going to drill the swing arm.

If its not a rude question how much for the Brembo parts and how much for the spacers? Do any other Brembo caliper have the same bolt spacing as the 999?

You can PM me if you like.

[yorkie_chris]

See first pic I posted in here; that round thing with 3x black bolts will go on inside of swingarm. I think I will need to find a 90degree air drill or a flexy-drive thing to get bolts straight though.

DavieSV made these for me, I have pointed him in direction of this thread.

I will be making some small alterations to drawings depending on some final measurements but we will see. If he isn't interested in selling a kit then I'll get the drawings hosted somewhere so you can have your own made.

[maviczap]

YC, ok, at least if I have the spacers, then I can take my time finding the caliper and mount. I already have a spare swingarm

I still have to do my front end swap. I have all the parts, just no heating in the garage :(

[Holdup]

You going to keep that caliper clean YC? :p

[yorkie_chris]

Caliper for me was about £45 IIRC (including hangar, bolts and pads).

Same caliper is on 749 and 999. 748/996/916 one looks very different and I think would be more work.

[yorkie_chris]

You going to keep that caliper clean YC? :p

I doubt it but maybe I will clean swingarm, cheap way to reduce unsprung weight :-P

[Holdup]

Haha, does look like you could shave another pound of by removing some of the c**p from it

[yorkie_chris]

Pah. You should see other side. That is 30,000 miles use with no cleaning.

[dyzio]

Looks like the one aprilia uses too:

http://img31.imageshack.us/img31/9962/attachmentiu.jpg

[yorkie_chris]

Oh yeah. It is same as cagiva raptor too.

[maviczap]

Well that gives me a few options to hunt for. Although £45 ain't too much wonga anyway

[yorkie_chris]

http://cgi.ebay.co.uk/DUCATI-749-2008-REAR-CALIPER-CARRIER-BRACKET_W0QQitemZ390107913744QQcmdZViewItemQQptZUK _Motorcycle_Parts?hash=item5ad43e5e10

one there

[maviczap]

OOh tempt me not Satan with you beatiful anodised parts :smt112

[yorkie_chris]

Out with the old:
http://img690.imageshack.us/img690/6343/dscf7376q.jpg
One very tired ZX6R shock. Was beginning to feel well short of rebound, and they are too short as new. Tried to get spring off and decided I can't be rsed. It will wait until I can be bothered to refresh it with new oil and gas then sell it.

And in with the new:
http://img191.imageshack.us/img191/9983/dscf7378.jpg

Obviously shock works better with a spring on it, but I wanted to check for any interference between the exhaust and the rear caliper.
So, I took spring off (easy on penske, just wind preload all way off and remove clip! Showa needs spring compressor). Set the ride-height adjuster to minimum and bolted it all together "dry".

Then you can move swingarm by hand to check its entire arc is clear of interference. not much force is required because you are only compressing nitrogen in shock. You would not be able to do this with the spring on!
(straps just there to hold it, you can move swingarm by hand).
http://img215.imageshack.us/img215/9676/dscf7379s.jpg

This check turned up slight interference between swingarm and exhaust but only when the bump-stop on the shock was compressed about 5mm and at min ride height.
http://img686.imageshack.us/img686/6599/dscf7380a.jpg
I will probably use it longer than min so probably won't be an issue, but now I know to space the can out 5mm or so to be on safe side.

[dizzyblonde]

Its no good putting sparkly baubles on it...if you ain't going to polish the rest of your turd! ;-)

[maviczap]

Maybe from an Ugly Duckling............. :rolleyes:

[yorkie_chris]

Tuned engine + decent suspension + battered looks = surprised riders of shiny bikes

[Wideboy]

good now clean it

[dizzyblonde]

yeah yeah like whateva....remember there was once a turd that YC polished for a Dizzyblonde, and it got all the baubles, and new suspension and Dizzy loved her again....a walking testament to YCs handiwork...


Now get cleaning, no I ain't volunteering....I'll threaten you with Pete n Lissa! YOU KNOW WHAT HAPPENED THE LAST TIME. :-)

[yorkie_chris]

Lol you come and clean it, it will save me getting dirty putting it back together :-)

[dizzyblonde]

Only if you sheep dip it first!!!

[orose]

So you explained the straps... what are the knotted socks there for?

[yorkie_chris]

To stop the remote reservoir getting battered while I am messing around with everything.

[orose]

pfft... that needed much more mad science than that

[yorkie_chris]

Errr, the smell keeps the suspension demons away? Or "what, you think used shock oil smells like that on its own?!"

[orose]

I am half expecting to come across one of these threads and find you doing something that involves jump leads and a lightning conductor one day. I guess that'll be the project you mentioned in the performance parts thread...

[yorkie_chris]

Lol "that project" is on hold until I can get a cheap crank and rods. If anyone has some they can lend me let me know, I promise I will give all of it back even if it means walking down road with metal detector :-P

[DavieSV]

Looking good :D

Every thing looks like it fits OK

So it's just down to fitting the torque pin then is it?

[yorkie_chris]

Yep that's the last bit. Need to borrow one of those 90 degree drills though as neither a small cordless or an air drill fit in between the arms of the swingarm

[DarrenSV650S]

I've got an angled chuck. But far away though :(

They're only about £20

[dyzio]

Is it this calliper's fault or the way Aprilia/Cagiva route their rear brake lines that makes this one a pain in the rse to bleed?

[yorkie_chris]

Just the wops being wops. Those calipers on cagiva bleed fine when you move them to get line facing right direction.

[yorkie_chris]

Now to take it all apart again...

[yorkie_chris]

http://img51.imageshack.us/img51/5287/dscf7556.jpg
Mmmmm purdy

http://img62.imageshack.us/img62/1452/dscf7552.jpg

Clean linkage, you won't see that too often! All nicely greased only to now notice that the shock bottom bearing is flooked and there's about 2mm of up and down play in the 'arm without compressing shock. Bugger!

[dizzyblonde]

Maybe purddy, but its still like putting blingy earrings on a turd ;-):smt043

[yorkie_chris]

Perhaps, when you see it in action you might understand my motivations are somewhat different than putting on shiny crap that does nothing.

[dizzyblonde]

Most of my 'shiny crap' does do something ;-)

It would actually be nice to see the rest of your bike compliment the money spent on your new suspension, and engine thingybobs, it really would.
GO buy a new tank, and a get a proper fender extenda,,,,in fact I'll buy you one of those for your birthday:p Pamper her, and get that GPZ done so you can rat around on that.



ps you know I'm only on the wind up

[yorkie_chris]

Lol when I get time I am going to convince MYC that helping me shape lots of body filler and stuff is arty and make a carbon-kevlar tank like here (http://www.bayarearidersforum.com/forums/showthread.php?t=145975&page=23). Maybe then I will even clean it ;-)

It also needs a full rewire, but that's not causing any problems yet so it can wait until the GPZ has proven its reliability. (that POS is getting MOT'd this week, god I must be old. £270 TPFT for both bikes...)


And as for shiny crap on your, yeah right I'm sure polished rims and top yoke makes you faster LOL

[dizzyblonde]

£270 TPFT?? You aren't old enough yet ;-)
You need to be getting £280 FC for both , THEN AND ONLY THEN ARE YOU OLD!!!

[yorkie_chris]

http://img21.imageshack.us/img21/597/dscf7560p.jpg

Lots of bits of fork.


The state of the inside of them 600-SRAD forks was disgusting, looked like ditch water and there were bits of crap stuck in between all the valve shims. No wonder they felt squishy!

[orose]

I'm more worried by the sandwich remains on the plate - is that brown bread?

[yorkie_chris]

Yes but don't worry, plenty fat in the bacon to make up for it.

[Lozzo]

You've gone down in my estimation... brown bread is ghey no matter how much fat you leave on the bacon.

[dizzyblonde]

MissYC needs to get him to lose weight somehow...slipping brown bread around bacon butties disguises healthy eating ;-)

[yorkie_chris]

Here's a question, should I fit upside down forks or normal?

[STR]

i would say upside down

[Holdup]

usd

[Lozzo]

USD, to counter the gheyness of your brown bread fixation.

[Bibio]

GSXR 600 k1-3 RWU.. or you will become a tart.

[DarrenSV650S]

have one usd and one rwu.... just to be different

[yorkie_chris]

GSXR 600 k1-3 RWU.. or you will become a tart.

You saying K1-K3 just to be difficult? I have 96-99 already on for nearly 2 years. I am just revalving and springing one set or the other...

[Bibio]

yes coz i know its completely different... :-)

[yorkie_chris]

yes coz i know its completely different... :-)

What is completely different? (except for different type of caliper and anodised cap)

[Bibio]

and wheel, mudguard, spindle+ collar, bottom & top yoke, discs.

[punyXpress]

yc - you been making gaskets out of your brown bread again ?

[yorkie_chris]

and wheel, mudguard, spindle+ collar, bottom & top yoke, discs.

So yes just awkward then and there's no actual performance reason to use owt different to the 600-SRAd ones I have now!

[missyburd]

MissYC needs to get him to lose weight somehow...slipping brown bread around bacon butties disguises healthy eating ;-)
As does using semi-skimmed milk instead of full fat for a banoffee pie :P

I'm a little concerned about how he plans to convince me to help with the manufacturing of carbon fibre...although it does look fun so it probably won't take that long...I'm looking forward to the paintjob we came up with last night for the SRAD :smt029

[dizzyblonde]

I'm looking forward to the paintjob we came up with last night for the SRAD :smt029

Oh please say its going to go right with those oh so ghey race leathers he bought.....preettttyyy pleaaaaze



http://www.guzer.com/pictures/pretty_please_cat.jpg

[missyburd]

Oh please say its going to go right with those oh so ghey race leathers he bought.....preettttyyy pleaaaaze

nah, the GPZ already matches those, shame its never going to see a track!

[dizzyblonde]

wish you'd hurry up and get him photo'd with them on we're all dying to laugh!

[Bibio]

So yes just awkward then and there's no actual performance reason to use owt different to the 600-SRAd ones I have now!

:smt023

your getting all 'bling eyed' stooooooop it.

[yorkie_chris]

True. Sell the 750 forks to someone who likes shinyshiny it is then.


Tell you what though the 600 ones are a MAJOR pain in the arris to remove the oil lock pieces from.

[missyburd]

wish you'd hurry up and get him photo'd with them on we're all dying to laugh!
I'm just biding me time lassie, biding me time :-P

[yorkie_chris]

http://img684.imageshack.us/img684/4261/dscf7569.jpg

Out with the old.

[yorkie_chris]

http://img202.imageshack.us/img202/3258/dscf7593.jpg

Fork pistons resurfaced to get rid of comp. free bleed and ensure good stack sealing.

http://img205.imageshack.us/img205/1349/dscf7595.jpg

New shim stack.

http://img42.imageshack.us/img42/2922/dscf7596.jpg

Valves assembled ready to fit to cartridge

[Lozzo]

£270 TPFT?? You aren't old enough yet ;-)
You need to be getting £280 FC for both , THEN AND ONLY THEN ARE YOU OLD!!!

Wrong - you need to be paying £256 FC on four bikes, them being a modified CBR600FW, modified 250 Yamaha, a 250 Suzuki trailie and a near new Versys, with no alarms and no added security systems. All modifictions declared as well.

That's when you know you're old!

[yorkie_chris]

http://img30.imageshack.us/img30/9984/dscf7732.jpg

New hose for back, stock one was way too long.

first attempt at fitting ends to braid, not as bad as I thought.

[maviczap]

Ah, I was waiting for an update on this YC

How about a pic of how you secured the pin in the swingarm, for the caliper hanger?

Any issues with the spacers that DavieSv made for you?

[yorkie_chris]

The spacers were done to my dimensions, the only issue is that the caliper is not central by 0.5mm or so, which makes absolutely no difference but I intend to update the drawings. Only time this would matter is if you had very thick pads with very little clearance to disk.

Can't fault DavieSV's machine work, surface finish was pristine and everything measured bang in the middle of tolerances I gave on drawings. He's a professional at this no doubt about it.

Yeah I have a pic somewhere I think. You can see pin in post #42, it is just 3 holes drilled for flange. I think this is probably too elegant a solution for the job in hand but hey ho.
Also read here
http://www.twfracing.com/vbforums/showthread.php?t=488

[fastdruid]

http://img202.imageshack.us/img202/3258/dscf7593.jpg

Fork pistons resurfaced to get rid of comp. free bleed and ensure good stack sealing.

Not tempted to modify them at all for better flow?
http://www.peterverdonedesigns.com/images/content/motorcycle/showa%20high%20flow%202.jpg

http://www.peterverdonedesigns.com/highspeed.htm

Druid

[yorkie_chris]

No, I don't think any cavitation caused by sharp edge there is major enough to cause any issue, and these ports are huge. KYB works "OK" with far smaller ports. Personally I think mods like that would be great on an MX bike or something which could blow through travel so fast but for road I'm not so sure.

If I can tell any limitation in this area later then I pull them in bits again and mod valves. But lets face it I am no expert enough to notice.


And the serious change is in the valve stacks, a massive increase in rebound damping for a start. It is going to be like comparing chalk and cheese anyway, and I wouldn't want to make an incremental change like this unless I could do before and after testing.

[maviczap]

Yeah I have a pic somewhere I think. You can see pin in post #42, it is just 3 holes drilled for flange. I think this is probably too elegant a solution for the job in hand but hey ho.
Also read here
http://www.twfracing.com/vbforums/showthread.php?t=488

Had a look at you pics and the TWF thread. Couple more questions

1. You used your Sv back wheel if I'm correct?
2. Instead of drilling the swingarm for the fange, couldn't you have got someone to weld a pin in the same position? Or is it stronger and easier to do it this way?
3. Did DavieSv make the 3 hole flange as well? I didn't doubt his skill in making the spacers, just everything alined correctly from your dimensions

Apart from these questions, I have a spare swingarm in the garage that's just asking to be modified :p Although I'll need the measurements to ask DavieSv to make me the spacers

[yorkie_chris]

yes, I do not see benefit of using gixxer rear wheel. I am slow enough on -160 tyre LOL

Welding alloy is a pain in the 'rse. Far easier to just drill and bolt.

Yes davieSV made the flange too, look at the picture in my original post in this thread, that is flange.

[maviczap]

Welding alloy is a pain in the 'rse. Far easier to just drill and bolt.

Yes davieSV made the flange too, look at the picture in my original post in this thread, that is flange.

1. Agreed

It wasn't clear if Davie had made the flange

Cheers YC :smt023 Perhaps I can have the dimensions of all the bits DavieSv made for you, unless he has them?

[yorkie_chris]

Yeah he has drawings but there are some small changes to be made, if you are in no rush I would rather make these changes before anyone else sees the details. There is enough bunfighting on SV boards about misaligned calipers as it is :-P

[maviczap]

Yeah he has drawings but there are some small changes to be made, if you are in no rush I would rather make these changes before anyone else sees the details. There is enough bunfighting on SV boards about misaligned calipers as it is :-P

No problem YC, I've got enough to do at the mo and I've spent a lot of wonga lately :rolleyes:

I'll buy the caliper hanger as its still on the bay :p

[yorkie_chris]

I would definitely budget for another short length of brake line too.

[yorkie_chris]

Small progress, but it should be finished tomorrow.
Set the sag up, put some other bits back on. Stuck some new rubber on the back.
Hit a GSXR K5 sidestand with the welding stick until it worked. These supposed to work without many mods*, but I am absolutely b*ll*cksed if I can see how.
http://img32.imageshack.us/img32/8651/p1018344.jpg

*I.E not chop the bugger in half and weld it back up

[maviczap]

Woi is u fittin a GSXR side stand? Longer?

[dizzyblonde]

Cause hes worn the other one spinning the SV round on the other 360 degrees,?

[missyburd]

seems to have sorted the stand now. Just heard the SV come back to life, how we've missed it!

[yorkie_chris]

Longer?

that

Cause hes worn the other one spinning the SV round on the other 360 degrees,?

that too

Not much space at the bottom of the driveway, so the bike gets picked up and spun round on the stand twice a day.

[dizzyblonde]

Thought so. That driveway is one big pain in the 'arris.

[yorkie_chris]

But with extra ride height with penske shock it was leaning over to knee down level on sidestand lol.

[dizzyblonde]

Extra ride height? Sure you don't need stilts too, to get your feet on the floor?

[yorkie_chris]

Rode it to uni today. Feels good :-D

[yorkie_chris]

Had a bit of a play around on the way home. The new rear shock is awesome, after backing off on the rebound from the baseline it feels much nicer. I think it was packing down a bit before cos of the cold. One corner where you can usually make the back kick out and misbehave it was completely planted.
The front still isn't quite right, I think just too much low speed because it's bloody freezing, but it is a completely different bike.

Nearly put my back out at the petrol station catching it when it fell off the stand though... works good on flat ground. Not so good on an incline!!

The whole bike just feels better, there's no pitching movement on hitting a bump and the front end doesn't ping back up a yard before the rear. I can't wait to ride this properly when we get a day where the tyres will warm up! :-D


And the back brake seems fine. Plenty feel with it and more total force than you need. I tried a couple of big boots on the pedal, locking the wheel momentarily at speed and the torque pin hasn't sheared off or anything.

[yorkie_chris]

Had a bit of a play around this morning.

Suspension feels absolutely spot on, only let down now by a worn front tyre. Some viper sports on the way which have a pointier profile :)

Settled on 22mm static sag at front, 10mm at rear.
Rebound @ 1 1/8 front, 17clicks rear
Comp @ 1 1/8 front, 10 rear.
Shock length around 355mm.

After a load of fettling, shock settings have ended up right back at the baseline that Zoran recommended for me! :smt082


Fookin brilliant. The way you can now hit bumpy corners with stupidity and it still remains pointing in the same direction, you can wally the throttle and brakes and it so far seems completely impossible to upset :-D

[missyburd]

Aha, happy SV :D Good to know the filthy beast got a beating on the way back home after trundling along at slow miles an hour for my sake :rolleyes: :-P

[yorkie_chris]

tell you what I'm sure it handled a lot better other day when the tank was near empty

[BanannaMan]

Just seen this,
(don't have time to read everything)

You have been fiddling with the suspension a bit !
Well done indeed. I'll bet it handles great!

Shame Suzuki never saw fit to put decent suspension on the SV from the factory.
Would have been cost prohibitive I'm suppose.

Looks like you have her well sorted now!
Except the part where you forgot to clean rest of the bike. :p
Just remember...
















If beauty had no function, you'd have settled for some ugly bird long before you met MYC. :p


;)

[Lozzo]

Not much space at the bottom of the driveway, so the bike gets picked up and spun round on the stand twice a day.


My preferred method of turning big bikes around too. I did the same with my Gixxer Thou K1 at my old place cos the back garden was quite tight to get in and out of and once on the patio it made sense to turn it round before parking it up for the night. The stand survived 18 months of that with no damage. ZX9R stands are a little more fragile and mine bent out of shape after 6 months of that abuse.