Yoshimura GSX1135R (EFE) Project

[Mindless]

K I've got a couple quick questions about your front end...First off...what kind of forks are those off of? they look like ohlins but I can't tell...(very nice though) and second. Did you machine the triple clams yourself or buy them? also your handle bars...I have a similar set but no risers...I'm in the middle of machinning them and I was wondering if you just bought them or not.

Front forks are from a Hayabusa, 2006 years model. Found a complete fork with calipers for virtually nothing, just couldn't pass it up. Thought about buying a set of Ohlins but that's usually between $1000-1500 for a used set.

As for the triple clamps; I assume you're referring to the mounts on the swingarm (and frame) for the shocks? Made them myself.

I bought the handlebar and risers from a local shop that sells anything from bike parts to hand-held powertools. Cost about $100 for the kit. The handlebar is a regular 28mm MX-handlebar (Fatbar).

 

[Yamazukahondi]

As for the triple clamps; I assume you're referring to the mounts on the swingarm (and frame) for the shocks? Made them myself.

No no, the "triple clamps" are the clamps that hold both fork tubes to the steering head. the two big aluminum parts of the forks that aren't forks.

 

[Mindless]

No no, the "triple clamps" are the clamps that hold both fork tubes to the steering head. the two big aluminum parts of the forks that aren't forks.

Oh, my bad. Not really into the English (American) terminology yet when it comes to these things. I only know them by the name "yokes".

They were custom made by a friend of mine. I drew them up and supplied the materials and he milled them out for me.

 

[Yamazukahondi]

Oh, my bad. Not really into the English (American) terminology yet when it comes to these things. I only know them by the name "yokes".

They were custom made by a friend of mine. I drew them up and supplied the materials and he milled them out for me.

Awesome, I was thinking about doing it but I wasnt sure about it but now I see someone else with them I'm certainly gonna do it...do you know how thick they are from top to bottom?

 

[Mindless]

Awesome, I was thinking about doing it but I wasnt sure about it but now I see someone else with them I'm certainly gonna do it...do you know how thick they are from top to bottom?

Top yoke is 22mm thick and bottom is 40mm.

You'll have to do careful measurements though so you get the correct lead (distance between the center of the steering column hole and the center of the fork legs) as well as a bunch of other stuff depending on what wheels you'll be using and what kind of break calipers.

 

[Mindless]

Small update. Ordered some fork extensions from one of my dads work colleagues (he's the lathe man). Turned out really nice and clean.

Ups the fork length from 730mm to 785mm.

Holes drilled in order to reach the fork adjustor's. Makes adjustments so much easier to do.

Matches the look of the forks pretty nicely too I think.

Gonna try and get that order for the new camshafts sent out before the weekend. Hopefully they'll arrive in a not too distant future then.

 

[posplayr]

Small update. Ordered some fork extensions from one of my dads work colleagues (he's the lathe man). Turned out really nice and clean.

.

That is totally trick . I think I would be temped to annodize gold or powder coat black the extensions but that is the coolest set of forks I have seen for a GS.

 

[posplayr]

for got to ask; how much for those extension; never seen them except maybe Salty Monk was thinking about something similar

 

[Mindless]

for got to ask; how much for those extension; never seen them except maybe Salty Monk was thinking about something similar

Freebie. My dad and the guy who made them trade favors from time to time, this was one of those favors.

 

[posplayr]

Freebie. My dad and the guy who made them trade favors from time to time, this was one of those favors.

Ok cant figure out; is there a split in the extension to allow it to clamp on to the fork?

 

[Mindless]

Ok cant figure out; is there a split in the extension to allow it to clamp on to the fork?

Nope, no need for it really. 99% of the stress is taken up by the lower yoke, steering stem and lower bearing. The top yoke is just there for stability, and the fit of the extensions is super-snug so it can't really move around a whole lot (a fraction of a millimeter).

I might use some Loctite bushing-glue to fix them in place just in case though.

 

[posplayr]

Nope, no need for it really. 99% of the stress is taken up by the lower yoke, steering stem and lower bearing. The top yoke is just there for stability, and the fit of the extensions is super-snug so it can't really move around a whole lot (a fraction of a millimeter).

I might use some Loctite bushing-glue to fix them in place just in case though.

Well I believe you have well fitting pieces there, and you obviously beefed up the lower but if there is any wear in the upper extension, then it will continue to open more and waller out. Is it made of stainless or aluminum; hard to tell?

If it is under bolt tension then the load stretches the bolt , but it just returns to it's original length after the load is gone. A tight fit can just wear a larger hole if there is any movement. Once its starts it has to get bigger.

 

[Mindless]

Well I believe you have well fitting pieces there, and you obviously beefed up the lower but if there is any wear in the upper extension, then it will continue to open more and waller out. Is it made of stainless or aluminum; hard to tell?

If it is under bolt tension then the load stretches the bolt , but it just returns to it's original length after the load is gone. A tight fit can just wear a larger hole if there is any movement. Once its starts it has to get bigger.

High quality dural aluminium. Doubt there will be any noticeable wear.

 

[Mindless]

Got some minor work done today on the bike. Got some footrests for it the other week so todays mission was to figure out where I wanted them on the bike.

After some measuring yesterday we went back to the workshop today and cut out some plates in 4mm stainless steel and drilled a few holes. Kind of nailed it on the first try.

Offset about 10mm downwards and 40mm backwards from the center of the frame tube. Didn't feel bad at all.

These plates were just for mock-up and trying to figure out a good angle for the footrests. The real deal will be some beefed up aluminium plates.

Here's a side view of the bike with the fork extensions on. Made all the difference for the riding position and stance of the bike.

Now all that's left to do is some more frame bracing and finish up the subframe. After that it's just a matter of sending it off for blasting and then to the powdercoaters.

More progress to come in a few days.

 

[Mindless]

Small update. Went to the workshop to weld in the last two frame braces.

Took a while to work out how I was going to weld the insides, but after a while I managed to figure it out and get it looking pretty good.

However, after welding it all in place, my dad stepped back and said "Wait... can you see something wrong?". I was like "What? No?", but upon closer inspection, the left side brace was turned upside down (the wrong way). The brace on the right side has a 45 degree angle to the frame tubes, the left one is abour 60 degrees.

Oops... :|

Oh well, no big deal. You can hardly tell it's wrong. If anything, it'll make putting the engine in easier.

 

[Bad Kaw]

See that!? You know you're having a "blessed" build when even your mistakes are cool and work!

-KR

Great build!

 

[Mindless]

See that!? You know you're having a "blessed" build when even your mistakes are cool and work!

-KR

Great build!

Hahaha, you might have a point there!

Went down to the workshop again to do some of the last welding and fabricating on the frame. From the start I intended to make a cross-brace (an X) in the frame where the airbox was, but for some reason I forgot all about it. Well, yesterday I remembered it so I got to work and after a while I had something looking like this.

Was a real pain to weld some spots and the protective gas (Argon) was acting up for some reason. Oh well, got it looking pretty good in the end. Will see if I go back down tonight or tomorrow to try and finish everything up.

Also got some packages in the mail today. The exhaust and the ever elusive quarter fairing. Custom fee on the fairing was huge (in addition to the massive shipping cost) so it turned out kinda pricey in the end, but the final product was very nice. Can't say I'm unhappy with it.

And yes, that's the Z1R's fairing if you're wondering.

And now for the exhaust. Excellent build quality and finish, well beyond my expectations. However, there was a slight problem.

It's in carbon.

 

[Mindless]

I wasn't really angry about it. It still looks great, but it wasn't what I had ordered. So, I shoot the guy a mail, explaining the situation and asking what we should do in order to resolve the situation.

Within an hour he replied, apologizing for his mistake when packaging it. In order to make it up to me, he's gonna send me the stainless exhaust I ordered free of charge with EMS (Express Mail) and let me keep the carbon exhaust. Now that's good customer service.

Despite this mishap, I highly recommend him. The exhaust is quality through-and-through. No loose rivets or sloppy welds. If you want a cheap and nice exhaust - contact him.

For the exhaust I had ordered a Yoshimura foil sticker (looks cooler, period).

Hm... shouldn't look half bad on the exhaust I thought... well, I was right.

I think I'll be using the carbon exhaust.

 

[posplayr]

I wasn't really angry about it. It still looks great, but it wasn't what I had ordered. So, I shoot the guy a mail, explaining the situation and asking what we should do in order to resolve the situation.

Within an hour he replied, apologizing for his mistake when packaging it. In order to make it up to me, he's gonna send me the stainless exhaust I ordered free of charge with EMS (Express Mail) and let me keep the carbon exhaust. Now that's good customer service.

Despite this mishap, I highly recommend him. The exhaust is quality through-and-through. No loose rivets or sloppy welds. If you want a cheap and nice exhaust - contact him.

For the exhaust I had ordered a Yoshimura foil sticker (looks cooler, period).

Hm... shouldn't look half bad on the exhaust I thought... well, I was right.

I think I'll be using the carbon exhaust.

That looks very nice. I have some of those in raised lettering that I was going to add the two rivets as well.

It is also pssible to also find a period NOS one as well but they are pretty few and faw between.

Nice work finding that pair of cans.

 

[tejasmud]

I have a couple of the Chinese canisters for one of my other bikes, 3 bolt flange type, one oval carbon fiber, and another stainless/iridium color. Cost me around $100 USD each. The Yoshi badges/stickers came with them as well. Not bad quality at all.

I agree with the rivits, better yet, the sticker needs to be put on a thin piece 0.025" thick or so of stainless nameplate material, drill some holes and then rivited to the canister.