2020 has been a heck of a ride so far.  We have had some really good development with the Sv650’s in the off-season. Seems we be in a holding pattern with at least the first round of the Twinscup most likely to be delayed.  
 

Back a couple months ago we got a call to see if we’d be interested in helping a rider with his program for the FZ.  Having spent plenty of time on the FZ and having tons of parts on bike in the MA paddock it seemed like a great opportunity.
 

The bike arrived and looks like we have our work cut out for us.  It was determined it would be better to start with a new frame as a clean slate.  

From the original bike we will be using the following parts:

-Engine Cases 

-Forks

-Shock

-gauges 

-aRacer ecu, wideband and quickshifter  

-Rotors

-Calipers and lines

 

The rest will need t0 be replaced...

Should be a fun build.  Stay tuned for  the tear down and inspection to build from the frame up.  

 

 

 

 

Looking forward to this!

Cant wait to see it all transform!

Tear down and inspection was pretty interesting.  I was told the bike overheated and the engine made some noise...quick start just to confirm and yes definitely does have an unusual noise from the engine.

Started taking inventory of things to address as I was disassembling to making a list of things to order. 

Numerous wires cut without insulating, wires wrapped in various tape products, zip ties for clamping the the intake to the throttle bodies.  Oh this will be special I can tell...

 

Pressure sensor for oil isn't hooked up, why would you want that?  It could possibly save components, built engines are cheap.

Plugs for stock narrow band O2 sensor are apparently expense (or not here are the ones I use) just cut the wires off and leave the sensor there...why not. 

Under tray apparently didn't fit.  I'm no police officer but I believe there are signs that a significant struggle ensued.  Not sure who won the fight or how the other party looks but the carcass of the victim appears to be left as a warning on display for others. 

Made some more progress and got the cases stripped down to send out.  To Millennium Technologies to have replated and sized for a set of custom slugs we had made by JE.  
 

Some of you might have seen them on Instagram or Fb.  For those that didn’t here they are.  

 

~15 grams lighter than the Wiseco off the shelf item with a bunch of small features and changes we made over last season to the SV we thought might help.  

The engine was over all in terrible shape but nothing that can’t be fixed. I marked the bearings and assume they had to be the incorrect sizes but didn’t confirm. 

The crank and counter balance are grooved pretty good so new Yamaha parts will replace them. 

Making reliable power from these bikes isn’t hard.  It’s really pretty simple like I was talking with Mossrider last weekend and he has a great less is more mentality.  
 

Tomorrow I hope I’ll get to welding the mounts on for the subframe, right now they are just tacked in place.  Then will be tearing it down to prep the donor frame for paint.  

Took some time to redesign the rearset risers for the FZ.  Did some scans and oriented the scans to reference the top rail of the frame where I cut off the subframe to 2* referencing horizontal so I could make sure the adjustments were truly up and back in relation to the installed.

Im sure you could do it with a bob or something else but I just used the tools I have available and scanned the mounts, the stock plates and used it to reference and rebuild the risers designs.  3d printed some of the plates and installed to confirm. The slots in the plates allow for much more variance in the frames.

It also allows people to move the rearset where they would like.

 

Got the subframe welded on the bike today.

 Trying to see how I can offer these at a lower cost than fitting the coped smaller tubes and made some plates to dimple die.  

As well as modified the battery box/ undertray. Basically just clipping the sides off.  

The cross bar is located so it fits into a radius if the plastic.  No drama or butchery needed. 

working on new brackets to mount the relays under the regulator and rectifier.  

Started modding the airbox.  Doing a final print of the cover in PETG at a finer resolution. 
 

Started prepping the bike’s frame for paint. Going to have to see what kind of paint would be best to use, any suggestions are welcome. 

Powder coat if you have a guy that can...distant next would be a good automotive 2 part enamel. 

 

 

And cut them derned runners down.

2 hours ago, mossrider said:

Powder coat if you have a guy that can...distant next would be a good automotive 2 part enamel. 

 

 

And cut them derned runners down.

I thought about powder.  The only concern is being able to repair it.  
 

That being the single reason we don’t use it on industrial machines commonly and use wet paints still. damage powder coat needs to be removed entirely or at least in my experience.  
 

Also filling the vin stamp was a concern.  Any insights? 

2 hours ago, Spatt said:

I thought about powder.  The only concern is being able to repair it.  
 

That being the single reason we don’t use it on industrial machines commonly and use wet paints still. damage powder coat needs to be removed entirely or at least in my experience.  
 

Also filling the vin stamp was a concern.  Any insights? 

Bah, ain't much frame left to damage w/o subframe on there. These aren't show bikes, if you ding the powder, just touch it up with paint that is close. If you powder over bare metal that Vin will be visable.

After thinking about this a bit more, I think I'd just do whatever is cheapest and handiest in your situation. It's a race bike, it's beauty is its character. 

Here:

Yamaha 1329 Deep Purplish Blue Metallic #15 ( DPBM15 )

 

Powder coat would be my choice.  Had a whole race car frame done years ago.  If it gets scratched deep enough to rust in a crash, better check frame straightness too.  The coaters have ways to cap or cover areas that can not be coated.  I had a bunch of threaded pickup points that needed covering.

Little progress tonight after dinner.  Degreased the frame and the pressure washed it to get and debris I couldn’t reach.  
 

powder coating would have been a great option but didn’t want to have to blast the entire frame.   Not sure if it would fit in my big cabinet or not.

Customer wants black, I’m kind of into the grey.  

Not to derail your thread, but I'm curious as to why everyone seems to cut the subframe on this bike. Is it really that bad stock?

1 hour ago, br4nd0n said:

Not to derail your thread, but I'm curious as to why everyone seems to cut the subframe on this bike. Is it really that bad stock?

It's a significant weight saving on a race bike.

4 hours ago, stickshift said:

It's a significant weight saving on a race bike.

About how many pounds?

8 hours ago, br4nd0n said:

Not to derail your thread, but I'm curious as to why everyone seems to cut the subframe on this bike. Is it really that bad stock?

I’m honestly not a huge fan of cutting it off.   My personal bikes one I cut off and one still had the oe subframe.  Riding them back to back I couldn’t tell a difference. 

It’s not like riding a bike with aftermarket wheels vs stock.   It’s more if you tweak something you can replace it quickly. 

This was the chassis I used to make the first removable subframe.  Darren James ordered 2 bikes so I’m just setting them up the same for ease of spares. 

2 hours ago, phanomenal07 said:

About how many pounds?

Idk I’ll toss the info on my website when I put the subframe kits up.  Maybe 7-8 lbs 

19 hours ago, br4nd0n said:

Not to derail your thread, but I'm curious as to why everyone seems to cut the subframe on this bike. Is it really that bad stock?

Advantage of cutting it is when you crash on race track and need bike fixed. Easier to replace subframe than trying to straighten one that is in bad shape. 

So surprise to me midnight black is black with blue flake.  Guess next time I should take the paint chips outside and look at in daylight and not the fluorescent lights 😅

definitely nicer than the oe paint but not as nice as if I had let Parrish or someone more skilled than myself paint it.  

Definitely not as blue in the sun.  Really actually pretty happy about the color. 

Redesigned the fairing stay bracket for the bike last night.

I wanted better access to the fasteners and the mount to be able to hinge open.

Eliminated one of the stay bolts and reduce the size of the vertical height by using a dowel pin to locate the tube assembly on the mount.

I'll kick it around a couple more days before ordering material but I think that it wont change much.

Slept on it more and I think this is ultimately the way to go...

Slow going with a couple projects from my real job needing attention. 
 

I did machine the clamp and decided to redesign them again.  Just didn’t like the plain look.  

I’ll re-machine the new design this weekend.