GSXR 600 Road to 750 Track conversion - Now going fighter...

[Dean-J]

So when i picked this bike up she was majorly scruffy, had been thrown down the road in the snow and then left outside in the elements for a good few months... it had new fork seals, new wheel bearings all round, SC bearing, head bearings, calipers rebuilt, forks rebuilt, wiring fixed, and plenty more besides!

https://i448.photobucket.com/albums/qq205/deangte/20130607_122933_zpsfa8bbe8a.jpg

I Used her on the road for a few months, then painted the wheels white because all blue GSXRs should have white wheels!!!

https://i448.photobucket.com/albums/qq205/deangte/whitewhels_zps36aa81a5.jpg

https://i448.photobucket.com/albums/qq205/deangte/20130711_122330_RichtoneHDR_zpse1e32dde.jpg

in August i did my first trackday at mallory park ( RIP!) and then in September i did Bedford Autodrome ( kinda, brake failure put me out for half the day) and back to bedford again on 14th Oct ( damp and soggy but managed to have some serious fun on road tyres).

https://i448.photobucket.com/albums/qq205/deangte/AJP_3652_zpsb6b8dd6b.jpg

https://i448.photobucket.com/albums/qq205/deangte/AJP_7188_zps0994c5f6.jpg

https://i448.photobucket.com/albums/qq205/deangte/DSC_7716_zpsf4c8ad0b.jpg

https://i448.photobucket.com/albums/qq205/deangte/DSC_8538_zps04fb9df4.jpg

Track riding just blows road riding out the water for me, and is something i will be concentrating on next year, so the bike has had/is having some work done....

So the spec as it started:

Ohlins fork internals
Ohlins steering damper with Harris mount
ZX10R Radial master with mini reservoir
ZX10R levers
white Braided brake lines all round
White silicone engine hoses
Braking Wavy discs all round
R1 Monobloc calipers
K&N air filter
Power Commander 3USB
K4/5 GSXR 1000 headers
Harris Dual exhaust
Yoshimura bar ends
Yoshimura Number boards front and rear
Orange intake grills
heatproofed airbox ( dont ask me why....)
HRC race reservoir
R&G tail tidy
sol seat cowl
BT016 Pro rubber
and probably a few more bits i cant think of right now!

This month it has had:

Front forks refreshed
R1 Calipers stripped, cleaned, fitted with new seals and put back together with Bendix MCR pads, and APRacing 5.1 fluid.

Then a guy on another forum i use was breaking his track bike.... so i bought the low mileage GSXR 750 engine, complete with airbox, BMC filter, Yoshimura Hi-Rev race ecu, Sigma slipper clutch and the PC3 map off the bike ( will get it close enough til i get her back on rollers )

So, 600 came out....

https://i448.photobucket.com/albums/qq205/deangte/20131018_144431_zpsb86e0501.jpg
https://i448.photobucket.com/albums/qq205/deangte/20131018_165344_zps4d3f0e10.jpg
https://i448.photobucket.com/albums/qq205/deangte/20131019_142324_zps11887b4c.jpg

and 750 went in...

https://i448.photobucket.com/albums/qq205/deangte/20131025_165750_zps955bd67b.jpg

Few bits left to do before i can fire her up, have the exhaust, airbox, rad and fuel tank to go back on, coolant to refill, oil and filter change to do, Ignition to wire up as i have removed the key switch ( going to fit a hidden kill switch as well as the stock kill switch just for peace of mind) . Also have the PAIR, SET and STV sensors to resistor out to eliminate fault codes.

I also bought his race fairings, which need a fair bit of work, and then shall be repainted in 2k black, just for ease of repairs in future. They will get decal'd, but not made any decisions as to exactly how yet.... WTS!

May get a couple hours on the bike today, so will see what i can get done!
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[Wafer_Thin_Ham]

Looks cool.
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My Flickr

[RhynoCZ]

Cool project.
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'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[stu_m]

bloody hell you get about

[.....]

Looks good.

I took one look at that last photo and though 'Portsmouth'.

You're not in Fratton are you?

[P.]

A man who can change his exhaust mid lap, mad skills

Very nice mate If you are ever at Brands, let me know and I'll pop down

[Dean-J]

Ha, yes Joe, am in North end/buckland/whateverthisshitholeiscalled!

An paddy, if you think thats good, you should see me change my rear wheel mid lap
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[P.]

Are you going to be using it on the road at all?

[Dean-J]

i will be mate yeah, will be MOT'd without lights so daylight use only
____________________
Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[P.]

Good stuff

[Welshd1k]

hey pal you where selling the cbr600 f3 on ebay the other week (in bits?) I was the guy who told you what the forks where etc gutted I missed your engine though went soo cheap
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Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<

[Dean-J]

Yeah that was me bud. An yeah, it went bloody cheap, everythin is sold did tbh but hey ho, it paid for itself so thats all that matters.

got the bike fired up yesterday, all runs good aside from an oil leak on lh engine casing,which im off tonsort now!
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[Welshd1k]

[Dean-J]

Didnt I offer it to you for 180?! Lol

Oil leak all sorted,bloke who sold me the engine replaced the gasket when he took casing off to spray it up.... except he didnt remove half of the old gasket, which was causing the leak. Cleaned it all up, chucked it back together and she is all good.

No time to work on her now til the weekend so at this rate there wont be any test rides happening til sunday at earluest
____________________
Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[Dean-J]

Well, pretty minor update really....

Oil leak sorted, was a load of old gasket underneath the new one so wasnt sealing properly. Gave it a clean up and chucked it back together and all was good!

Finally got to take her for a brief test ride yesterday, certainly picks up quicker than the 600 did!

Do have one minor issue though, pulling away from a standstill is jerky until you get on the throttle... would a 525 chain on a 520 sprocket cause this? I will be replacing chain and sprockets ASAP, but didnt think it would do any harm in short term as pitch is still same?
Only other thing i can think of is the slipper clutch doing it, but PO says it never did with him, so im a bit lost as to what else it could be?!

Also got a box full of R&G goodies last night, so got them all fitted today ( cue boring pics!)

https://i448.photobucket.com/albums/qq205/deangte/20131101_115729_zps85621b85.jpg

https://i448.photobucket.com/albums/qq205/deangte/20131101_115719_zps3dc673e6.jpg

https://i448.photobucket.com/albums/qq205/deangte/20131101_112239_zpsa195a203.jpg

https://i448.photobucket.com/albums/qq205/deangte/20131101_103344_zps98d2d583.jpg


Also took my damaged fairings up to my bodywork guy, he reckoned there was 30hrs + in getting them repaired and ready for paint, and even at mates rates of £15/hr.......no chance!
So they have been chucked on the scrap pile and a full new set ordered which will be here week after next.

Paint scheme has been decided on also, im properly excited about getting it finished! Nothing too flashy, but a cracking and importantly,simple, scheme non the less!
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[stu_m]

top tip while its all apart

go through the wiring loom and clean all connections and make sure they are spot on

suzuki's wiring isnt the best and the last thing you want is loosing out on track time due to a shit connection

or even worse the engine dying mid corner resulting in brown trouser moment.....dont ask how I know

[Dean-J]

One step ahead of you there stu cleaned all connectors up when I oulled the original engine. Aside from a bloody good clean and new fairings, she is pretty much ready to go now.
Going to order a 520 chain and sprocket kit, dropping 1 front and +2 rear. Brings top speed down to about 155, but the increase in accelleration should make up for that nicely! Besides, not many places on track where ill really need the extra 15moh tbh!
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[Dean-J]

well.... pretty much ready to go i said on the 2nd of November....

yeah right!

Life has a funny habit of getting in the way eh, best laid plans and all that!

So whats happened since then...?

Well, massive rigmarole with the new fairings, so i ended up with 2 sets for the price of one, albeit one of them needing a dab of filler here and there!although i now have them pretty well fitted, they will get a final tweak tomorrow and i *should* be getting them sprayed up also if i have time.

paint ideas have changed, on account of my painter not being free until may/june, so im doing it myself in the obligatory matt black. Few nice decals etc should make it look decent enough. i hope. :/

I fitted a quickshifter, which really surprised me at how much better it is at changing gear than i am! Certainly keeps the front wheel up during upshifts, as i found out to my surprise when i rolled off well into mid 3 digit speeds and the front wheel hit the deck.... oops!

Transferred all my 525 C&S off the 600 onto this, and swapped the clutch plates over from my 600 engine = no more clutch judder.

Am back in the garage tomorrow to get a few bits done, need to fab up a bracket to mount the rear master cylinder in the correct position, get the rearsets fitted back on, rear brake bled up , fairings sprayed and fitted and then she is ready for her journey next weekend...

Taking her down to Verwood Crescent Suzuki to have her custom mapped and see what we can squeeze outta her... anything around 130-135bhp at the wheel and ill be happy. Im far more interested in making it a smooth,consistent ride than i am in peak bhp figures.

Then all being well, she WILL be ready for her first trackday in either March, or April... will update with some pics tomorrow and hopefully some good progress!
____________________
Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[Dean-J]

She is back from Crescent....

https://i448.photobucket.com/albums/qq205/deangte/DSC_0013_zps51c10ea5.jpg

140bhp ( im allowed to round up a 0.12 bhp surely!) at the wheel, that'll do nicely


Bad note from the dyno, the quickshifter is playing up randomly cutting the injectors as and when it feels like it.
The pc3 has some issues also, hence the big dip in the 2-3k rpm bracket. The dyno op did say this was exaggerated by very small 5-10% throttle openings so he could show me the problem. Tbh you'd probably never notice it on track, but ill get a PC5 fitted and have a wet map chucked on too, so every cloud has a silver lining and all that!


Didnt make as much progress with paint last weekend as i'd hoped ( bloody kids ) but did a little bit today, hopefully get em all finished on Tue/Wed. The finish aint perfect, but i dont really care, these are more of a tester for when i get my second set painted when my painter has room in the diary.

https://i448.photobucket.com/albums/qq205/deangte/DSC_0252_zps2a7b2027.jpg
https://i448.photobucket.com/albums/qq205/deangte/DSC_0253_zpsbd123fbc.jpg
https://i448.photobucket.com/albums/qq205/deangte/DSC_0005_zps2aa7d868.jpg
https://i448.photobucket.com/albums/qq205/deangte/Mobile%20Uploads/DSC_0254_zpswaa5f1qu.JPG

The red IS actually red, honest!

Also got a new rad bracket and rear master cylinder yoke nut F.O.C from a nice chap in the parts department, and a shedload of various stickers

And while i was waiting on the Dyno, Crescent were kind enough to let me take a couple bikes out to have a play on, first off a GSR 750:

https://i448.photobucket.com/albums/qq205/deangte/DSC_0002_zpsae045bc9.jpg

Then a Hayabusa:

https://i448.photobucket.com/albums/qq205/deangte/DSC_0003_zps9f50ef3e.jpg


Have to say they both surprised me, the GSR is a fantastic bike and i am very very interested in buying one in the next year or so funds allowing... ( I woulda bought it today, but wife said no to me getting it on finance )

But the biggest surprise to me was the 'Busa. Id always assumed that as it was so big and heavy and long, that it would just be a big comfy barge to ride and wouldnt handle very well at all... I was very, very wrong! definately not in 600cc supersports territory, but easy enough to fling around once you get to grips with it,Id put it on a par with say a TL or SV 1000... and that engine!!! like being strapped to a cruise missile!! Full power mode, into 2nd gear, whack throttle open and BOOM, warp factor 5 engaged captain!!

More to come in next week i hope!
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[Dean-J]

Booked the bike in on another Dyno next friday so i can do some tests find out whats causing this fuelling issue... more to come on that then!

Had an hour odd spare this afternoon so i got a bit more done bodywork wise..... once again, apologies for the terrible pic quality!!!

https://i448.photobucket.com/albums/qq205/deangte/DSC_0039_zpsgfrybaku.jpg

https://i448.photobucket.com/albums/qq205/deangte/DSC_0027_zpsf6hnfz5e.jpg

https://i448.photobucket.com/albums/qq205/deangte/DSC_0040_zpstiaraiui.jpg



Almost there!
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[t121anf]

What are your plans for the original headers?

[Dean-J]

Long gone mate sorry!
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[Dean-J]

Ok, so there has been a slight change of plan....

I finished the track build:

https://i448.photobucket.com/albums/qq205/deangte/DSC_0090_zps4f865ce0.jpg

https://i448.photobucket.com/albums/qq205/deangte/DSC_0091_zpse38c4132.jpg

Rode it once, realised how hideously uncomfortable it was on the road and figured id best buy a cheap road bike to keep me going until i can afford an FZ1.... So i bought this FZR 1000 exup fighter:

https://i448.photobucket.com/albums/qq205/deangte/DSC_0097_zpsfe546095.jpg

tatty, not to my taste, but it was great fun... until i started inevitably comparing it to the gsxr, which for the record is a better bike in just about every single way!

so what could i do.... i could run street plastics on the gsxr and just swap over for trackdays, that'd work - but M'eh.

OR, being that im a fighter kinda guy, i could strip the gsxr down, sell the track fairings etc, sell the FZR and fighter the Gsxr... HELL YES!

Now im not going silly with this build. I want to keep it classy.

The breif is simple:

It has to retain standard Geometry. It has to look almost factory from a distance. and everything has to work. No bodges, no quick fixes, it has to be right.

With that in mind i set out the plan.

Factory seat unit, with solo cowl and pillion seat should i want/need to use it.
Yamaha MT03 headlight unit with correct and subtle mounting brackets.
Custom top yoke visually matched with the factory lower yoke Both in gloss black, 50mm risers to clear fork tops and retain current suspension setup. Unbraced Fat bars.
New grips, cables, brake lines etc
Titanium bolts where possible ( discs,fork pinch, caliper etc)
Skin tank infill panels in Carbon fibre
Factory clocks in a custom Carbon fibre "pod"
Bikestyle undertray with built in lights ( just to keep people guessing)


Got these CAD drawings from the CNC shop today:

https://i448.photobucket.com/albums/qq205/deangte/gsxr-yoke_zpse3215e4e.jpg

https://i448.photobucket.com/albums/qq205/deangte/gsxr-yoke2_zps5bb6797c.jpg

Was going to get the bolts put on the front instead, but the more i think about it, am going to have him tap 2 threads in the front underside to hold a clock bracket, so keeping the bolts at the back makes sense.

Think im going to paint the yoke myself rather than have it coated, just so the finish matches the lower yoke perfectly.

Here is my paint inspiration:

https://i448.photobucket.com/albums/qq205/deangte/IMG1838-XL_zps1f8fcfd5.jpg

Not gonna quite get that colour on the wheels, paint i picked up is a 2 part base, factory honda paint, so hopefully going heavy on the top coat will get me close enough....

This is the colour ( I think!)

https://i448.photobucket.com/albums/qq205/deangte/honda-vrf-1200f-6_800x0w_zpsa1409da7.jpg

Hopefully going heavier on the top layer will get me a slightly more Wine/blood colour....

Was a time based decision really, i could get that paint mixed up there and then, or wait another week to have a more "candy" based paint made elsewhere. If i dont like it, ill just have em repainted.

Im stuck in 2 minds as to whether or not to paint the MT03 Headlight shroud white to match the Tank and tail, or leave it black to match frame etc.....
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[bikertomm]

I think you are mad

IMO it looked it's best when it had the original color scheme and white wheels

Why the change of plan to 'fighter' it instead of keep it trackworthy out of interest?


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07' Honda Hornet now full powaah! My guide on performing an oil change!

[Dean-J]

It'll still be trackworthy, just wont have fairings! I am going to buy an MHRA racing screen designed for honda hornet race bikes and adapt it for use when on track for a bit of wind protection.

The reason i didnt want it sat in the garage 99% of the year was simple, it has way too much money in it to just be sat there doing nothing!
To buy another bike for road use that was everything id want it to be id have had to lump out another 4-5k + on either a GSR750 or an FZ1, which was the original plan, but career change means i've had to make some sacrifices this year.

The Gsxr with all her tweaks does everything exceptionally well, it goes like stink, handles awesomely, and stops on a sixpence. Bonus with fighering it is it will be properly all day comfy, and look how i want it to whilst still retaining the power/handling/braking it currently has. Its a Win Win
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Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R