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2006 R1 swingar kat project

  • Thread starter Thread starter Guest
  • Start date Start date
Jed

There is a receiver on the arm that the hanger tongue slides into. That keeps the caliper from moving. It is free moving so you can adjust your chain slack. It doesn't bolt on.

Have a look above, you can see where I have machined the receiver and welded it to the bandit arm. the 93 gsxr caliper hanger slides into the slot and is held from spining when you hit the brake.

I have boxed below the tongue that slides intot the slot on the swingarm.

3f.jpg
 
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jeez, i feel dumb. i was looking at the eye on the swingarm for the shock:-$
 
OK,

The pivot on the R1 is 263mm vs gs 224mm without caps, which leaves me 39mm of material I need to remove. Problem is on the brake side that removes the entire bearing surface exept for 6mm. Beyond that is a little hollow due to this arm being cast.

I am going to line bore the pivot and sleeve it so I can fit new bearings. According to my Calc's it will just work. I will be fitting Gs needle bearings in it which need a 33mm diameter. The R1 arm is 37mm on one side and 34.8 on the other which I will enlarge to 35mm. This will give me a 1mm wall thickness on the brake side and 2mm wall on the chain side.

The 1mm doesn't concern me as there is plenty of meat around the pivot. Also I am fabbing a two piece sleave because one won't fit all the way through. I figured out a way to make the two and press fit them together on one side to add strength to the bearing areas of the sleeve.

Here is a drawing of what I need to do. In this one I have them threading together but I may just press fit instead and tack weld the end inside the pivot. This will be plenty strong and I suspect even over engineered.

sleeve.jpg


Here are a few pics of the pivot itself. You can see the hollow area the necessitates the sleeve. In the left pic the arrow points out what is left for bearing surface on the brake side. The swingarm uses a 30mm needle bearing on the chain side and a 20mm on the right.

http://www.robwilton.com/gsr/sl4.jpg
http://www.robwilton.com/gsr/sl3.jpg

sl1.jpg
sl2.jpg
 
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I have a second arm here too if anyone is interested in the mod I can do the two at the same time. I don't think I will want to do this again once I am done.
I have a set of 2" to 6" extensions for one of them too. not sure if I will use them as the R1 arm is already 2.5 inches longer than the gs. I also have a 6" busa rear wheel that can go with it.

this is not for the budget minded....email me if you are interested gs11sd@gmail.com
 
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have been working on the frame. Almost have the bracing done and have the under seat section done for electrics. Need a trip to the welders for lots of work. hid the rear brake mini-res under the seat, fabbed a camera mount under the rear cowl, battery box complete (sideways under side covers)

I am hoping to have the swingarm back from line boring later today. I want to maching up the sleeve this weekend.


http://www.robwilton.com/katuk/r1f4.jpg
http://www.robwilton.com/katuk/r1f5.jpg
http://www.robwilton.com/katuk/r1f6.jpg
http://www.robwilton.com/katuk/r1f7.jpg
 
Would you be willing fit a ZRX1100 swing arm for me? The ZRX is very similar to the R1, it's to wide and the pivot will need to be rebored to refit the bearings. I am thinking out loud right now and not really sure when I would acutally have you do the work.
 
Yeh, think we can work something out. There is a zx12 arm on a kat in my garage right now. I didn't so the mods though. There are some Brass bushings pressed in and it looks like there was a lot of material taken away.

Can I ask why you want the zx arm in particular?
 
Got my swingarm back today. will get some pics up of the boring work.
 
jwhelan65 said:
hangin tight on this one...great thread Rob! good stuff!
Click to expand...

Feelin a bit sorer today I bet. I always feel the worse two to three days after a stunt gone bad.

there are the pics of the boring of the pivot. NOw I need to reduce that with two sleeves as you see the blockage in the center.

r1pivotbore1.jpg

r1pivotbore2.jpg
 
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I would like to do something like this

attachment.php

(not my swing arm but similar)

on my gs1000 yosh replica at some point to give it that brace look Pops did back in the day
 
Got some more work done.

For the needle bearing sleeves I cut down a gs1100 pivot then machined the od to interference fit the r1 pivot. All I have to do now is narrow the r1 pivot by 40mm slide in the sleeves, weld them into place press new bearings in and machine some bushings and its done.

gsr1pivot2.jpg

sleeve1.jpg

sleeve2.jpg
 
MOre progress today. Bearings are in, mockup bushings are in. Swingarm is in.

I went another route today. I used the R1 bearings instead of sleeving. I did have to sleeve one side cuz the R1 swing bearings are two diff sizes and I had the smaller side sized to match the larger.
Everything pressed in nicely and the pivot bolt slides in perfectly. I used a set of bushings and the pivot bolt to press in the bearings and sleeve so everything was strait and true.
I tried two different pivots for a check and very nice fit. In the pictures you will see the bushings are too small to protect the bearings from dust... they are just for mock up. I will be turning some more bushings later.

I lasered the rear sprocket to get some idea of chain pain I was going to have and I guess all the measuring and comparing with the GS arm paid off cuz there is lots of room for the 520 chain. I also centered the wheel. In the pic you will see a 25mm distance between the tire and each side of the seat rails.

The next major prob is the brake hanger. Busa hanger is way to wide for this narrow arm so this will take some thinking

As far as the shock mounts, they are pretty close. Chain side mount can center up on fork but the brake side mount will hang a little over the outside edge much like the zrx11.

All in all I am very happy with the fit. I don't have to go to rear sets either if I don't want to. There is less rear brake pivot modding that on a bandit 1200 arm.
http://www.robwilton.com/r1/r1i.jpg
http://www.robwilton.com/r1/r1j.jpg
http://www.robwilton.com/r1/r1m.jpg
http://www.robwilton.com/r1/r1g.jpg
http://www.robwilton.com/r1/r1h.jpg
http://www.robwilton.com/r1/r1a.jpg
http://www.robwilton.com/r1/r1b.jpg
http://www.robwilton.com/r1/r1c.jpg
http://www.robwilton.com/r1/r1d.jpg
http://www.robwilton.com/r1/r1e.jpg
http://www.robwilton.com/r1/r1f.jpg

r1l.jpg
r1k.jpg

r1n.jpg
 
Very cool Rob, does the brake stay and caliper mount on top or bottom ?
Now that you have the R1 swinger, you may find some parts from an FZ1 that will work..I know someone who might be parting one out..:D
I see you snuck the Supersprox in there...is that a Yami sprocket?

jw
 
Threw some cases and tranny in today. Well, a whole host of new issues.

pivot case hits the engine so I will need to machine the pivot a little. Fortunately there is a lot of meat where it is contacting so it won't be a problem. its about three times thicker than the GS pivot.
Another issue is the chain clearance, surprise, surprise. it is contacting the inner surface of the bracing which is wierd since the wheel is centered in the swingarm. It must be offset on the R1.
I was using a quite thick 530 for mock up so a 520 (which is what I intend on using) will go a long way to solve the problem. Also, there is an ugly weld on the bottom of the frame where the peg stays are welded on. sloppy job aligning the pegstay. I will need to remove most of a section of weld plus some material and reweld. NOt a biggie.

Checked swingarm travel and it all looks clear. About 5 1/2" of travel befor that fat tire hits the subframe. The shocks only have 4.25" of travel so no problem there.

I have decided to keep the original pegs and not go with rearsets. With a black frame and swingarm and the matching angles of the stays and lower bracing on the arm I think it will look good.

the other prob with the 25mm wide 530 chain (as thick as my 630) is contact with the shock springs. I have a set of Fox shocks which are as wide as the ohlins I am going to use and chian is just touching the springs. The 520 will fix that as it is only 16mm wide.

Everything is connected to everything else. You guys who are thinking of doing some mods have to think of all the areas that may see impact from moving one thing or another. It doesn't take much of a mod on one thing to mess up two other things.

This R1 mod is threading the needle with the limited chain space, shock springs and frame but its doable. I very much want this arm to work as I am in to it now for close to 500.00 and that is with much of the maching done myself.
 
Rob

Rob

U R turning this into an art form :lol:.

That really is a fattie on the back there.

Love to see the detailed pics.

Pos
 
katman said:
Threw some cases and tranny in today. Well, a whole host of new issues.

pivot case hits the engine so I will need to machine the pivot a little. Fortunately there is a lot of meat where it is contacting so it won't be a problem. its about three times thicker than the GS pivot.
Another issue is the chain clearance, surprise, surprise. it is contacting the inner surface of the bracing which is wierd since the wheel is centered in the swingarm. It must be offset on the R1.
I was using a quite thick 530 for mock up so a 520 (which is what I intend on using) will go a long way to solve the problem. Also, there is an ugly weld on the bottom of the frame where the peg stays are welded on. sloppy job aligning the pegstay. I will need to remove most of a section of weld plus some material and reweld. NOt a biggie.

Checked swingarm travel and it all looks clear. About 5 1/2" of travel befor that fat tire hits the subframe. The shocks only have 4.25" of travel so no problem there.

I have decided to keep the original pegs and not go with rearsets. With a black frame and swingarm and the matching angles of the stays and lower bracing on the arm I think it will look good.

the other prob with the 25mm wide 530 chain (as thick as my 630) is contact with the shock springs. I have a set of Fox shocks which are as wide as the ohlins I am going to use and chian is just touching the springs. The 520 will fix that as it is only 16mm wide.

Everything is connected to everything else. You guys who are thinking of doing some mods have to think of all the areas that may see impact from moving one thing or another. It doesn't take much of a mod on one thing to mess up two other things.

This R1 mod is threading the needle with the limited chain space, shock springs and frame but its doable. I very much want this arm to work as I am in to it now for close to 500.00 and that is with much of the maching done myself.
Click to expand...
My GSXR swingarm contacted the cases with the added diameter also. I cut a bit off the cases, but I'm now reworking the enginine mounts to move her forward 1/4".

I'm also using a non O-Ring 520 for the clearance issues you just mentioned. They are considerably narrower.

You bike looks good.
 
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On the zx12 build I had the cases/pivot issue too. didn't take much to clear the two. I also moved the engine ahead a couple hairs by fabbing a couple new front mounts.
my 530 is 25mm and a 520 DID I have here on anothre bike is 16mm. I can't take it off the check on mine but will pick another one up for mocking up. I have room to move the swingarm over 1 or 2mm as well to help clearence with with lower bracing but don't think That will be necessary.

Hey Jim... I thought I was posting detailed pics? Which ones are you wanting to see?
 
OH... I see now. I just woke up when I read your post. Thanks and I will keep them coming.
 
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