PDX Piggy's No Name Build

[PDX_Piggy]

I thought I'd start a build thread from my FZ. My last bike, a 2007 SV650, was a great bike and I don't know why I sold it... Anyway, here is the link to that thread. This one will follow the same lines.

SV Build Thread: PDX_Piggy's "The Pink Piggy Build" - Suzuki SV650 Forum: SV650, SV1000, Gladius Forums

I bought the bike from a co-worker with 331 miles on it. He bought it for his wife and she rode it a few times and then let it sit. I picked it up cheap and took it home.

The tires were in good shape and still soft. The bike was covered in dust and needed a DEEP cleaning. I changed the oil, aired the tires and checked the brakes and all other fluids. I broke it in using conventional oil and then switched over to Rotella T6 after about 1500 miles.

I got some the2wheels adjustable levers, Lockhart Phillips flushmount turns up front and new riding pegs all around. I also picked up an undertail kit from Competition Werkes in So. Oregon.

I'll add some stock pictures tomorrow or the next day.

I worked some overtime, sold some things and got my wife to let me buy some toys. I picked up this:


http://www.flickr.com/photos/61272837@N03/7983316892/http://www.flickr.com/people/61272837@N03/

http://www.flickr.com/photos/61272837@N03/7983314447/http://www.flickr.com/people/61272837@N03/

http://www.flickr.com/photos/61272837@N03/7983317886/http://www.flickr.com/people/61272837@N03/

It's a front end from an 05' Kawasaki ZX6R. I picked up the forks, triples, rotors, brakes, master and front fender for $225.00 off CL. The Kawasaki triples weren't gonna play nice with the FZ steering head, so I found some 08' R6 triples in absolutely mint condition for $75.00 off CL. I bought some All Balls roller bearings to mate everything together. All in all I'm at about $360.00 and I still need a bare wheel, axle and stock spacers.

The ZX and R6 triples are identical in dimension except the stem length. The forks will mate up with the wheels, brakes, rotors everything without any modifications. The plus is that I have to do no machining at all. It's a very simple swap. The R6 triple is flat and took the Pro Taper fat bars very smoothly. I got the Pro Taper universal risers from a local shop in Portland and the grips / bar from Motorcycle Superstore.

The front end consists of the following:

2005 Kawasaki Forks / Tokico Brakes and Nissin Master / Kawi Rotors / Fender
2008 R6 Triples
All Balls Bearings (P/N 99-3538 and 99-3540-5)
Pro Taper Universal Low 1 1/8" Fat Bars
Pro Taper Universal Risers
Driven Grippy Grip

I can re-use the brake lines from the Kawasaki front end. They are still in great condition and are the proper length. I'll switch over to SS next winter. I'm gonna rebuild the calipers and flush the fluid.

I also picked up some new exhaust cans from Competition Werkes.


http://www.flickr.com/photos/61272837@N03/7983316039/http://www.flickr.com/people/61272837@N03/

http://www.flickr.com/photos/61272837@N03/7983315267/http://www.flickr.com/people/61272837@N03/

http://www.flickr.com/photos/61272837@N03/7983320862/http://www.flickr.com/people/61272837@N03/

I'm going to fab up a true Y-Pipe and a mount. I stuck the can on a piece of pipe and started it up. Man it sounds good! Gonna be sweet!

I also have some carbon side pods and a carbon front fender. I've got a set of Pirelli Diablo Corsa's that have been gathering dust in my garage. Gonna throw those on too. I'll post full glamor shots here in the near future. ENJOY!

- Z

 

[Gelvatron]

Looks cool wish I had space is be trying other stuff like that two damn apartments

 

[PDX_Piggy]

Looks cool wish I had space is be trying other stuff like that two damn apartments

Thanks buddy! I know the apartment feeling. Before I bought my house, all I had was an apartment carport. It sucked...

 

[FinalImpact]

Looks like a great start! :thumbup: Let me know if you ever need any help. I'm not to far away. . .

 

[PDX_Piggy]

Okay. Phase 2 is up and running. Got my upper fairing sold and picked up the VS-01 kit in black. Nice quality kit. Took me about an hour to install. I've got to trim down my wire and tuck everything nicely, but right now it's 100% functional.


http://www.flickr.com/photos/61272837@N03/8032923360/http://www.flickr.com/people/61272837@N03/

http://www.flickr.com/photos/61272837@N03/8032941445/http://www.flickr.com/people/61272837@N03/

I'm just waiting on my wheel to get back from the welder. It had a very small hairline crack I wanted to get filled in. Grabbing some missing hardware this morning and hopefully installing my new front end next week!

Thanks for looking!

 

[PDX_Piggy]

Got all the wires shortened, soldered, and shrink wrapped. Much much smaller and doesn't snag anywhere. Took me about an hour, but if I did it again, it'd probably only take me about 30 minutes. Wheel is back from the welder and came out great. I have all the parts for my front end conversion, minus some stainless brake lines. Painted the wheel semi-gloss black to match my rear FZ wheel. May take a few more weeks to get done... I have other projects going on now.

On a side note... I picked up a 2002 GSXR 1000 race bike for $450. Missing engine, forks, wheels and subframe. Has everything else. Gonna be my winter project. CLEAN TITLE and frame has two races on it. Came with boxes and boxes of parts (brakes, fuel, wiring, etc.) Anyway, to the goods!


http://www.flickr.com/photos/61272837@N03/8057493025/http://www.flickr.com/people/61272837@N03/

 

[jrevans]

On a side note... I picked up a 2002 GSXR 1000 race bike for $450. Missing engine, forks, wheels and subframe. Has everything else. Gonna be my winter project. CLEAN TITLE and frame has two races on it. Came with boxes and boxes of parts (brakes, fuel, wiring, etc.) Anyway, to the goods!

I'm trying to figure out what would be left with no engine, forks, wheels or subframe.... :BLAA:

Bodywork, main frame, brakes and a swingarm?

 

[PDX_Piggy]

I'm trying to figure out what would be left with no engine, forks, wheels or subframe.... :BLAA:

Bodywork, main frame, brakes and a swingarm?

Plus all the bolts and wiring. Once I have all the parts, it should take me maybe a week to assemble. The longest is gonna be fabbing up a sub frame for my tail. Really not that big of a project

 

[Zargof]

What model of the Competition Werkes cans are you using?

 

[PDX_Piggy]

What model of the Competition Werkes cans are you using?

03-05 R6 or 06-08 R6s

 

[aussiejules]

Looks like you are going to be doing a great project, we here all know why you sold the sv, you saw a fz and thought my life needs one of these no matter what it takes.

 

[PDX_Piggy]

Looks like you are going to be doing a great project, we here all know why you sold the sv, you saw a fz and thought my life needs one of these no matter what it takes.

That and I'm a sucker for a redhead

 

[aussiejules]

Im glad someone else has to say my wife let me.

 

[PDX_Piggy]

A small update...



http://www.flickr.com/photos/61272837@N03/8137349943/http://www.flickr.com/people/61272837@N03/
http://www.flickr.com/photos/61272837@N03/8137379990/http://www.flickr.com/people/61272837@N03/

http://www.flickr.com/photos/61272837@N03/8137378930/http://www.flickr.com/people/61272837@N03/

http://www.flickr.com/photos/61272837@N03/8137348859/http://www.flickr.com/people/61272837@N03/

http://www.flickr.com/photos/61272837@N03/8137348103/http://www.flickr.com/people/61272837@N03/

http://www.flickr.com/photos/61272837@N03/8137347327/http://www.flickr.com/people/61272837@N03/

 

[PDX_Piggy]

So I installed the All Balls roller bearing set into the R1 triples. The triples bolted up to my FZ6 frame without a single problem. The R1 stem was 1/4" longer, but after installing the All Balls lower bearing, it added just over a 1/4" to the overall length. The top nut goes on about 3/4 to full on.

I had to shave the R1 steering stops off and drill / tap new M8x1.25 holes. I have some bolts and solid spacers for my new stops. Works like a charm and set me back a whopping $4.06. I drilled / tapped new mounting holes for my headlight mount (VS-01 kit) and mounted it up. I used M8 bolts instead of the small ones included in the kit. It is much sturdier.

All the cables are routed, tire is mounted, everything is done except for one thing...

I have no mount for my ignition... and I cut the harness at the switch. I was thinking of doing one of two things...

1. Finding a new ignition and solder in to existing harness that I moved to the back of the bike

2. Run a SPST switch to bridge the power to the "on" position wire. I don't need the steering lock or even a key. I parked in my garage 100% of the time and we have secured covered parking at work. If I ride, I don't leave my bike outta sight or unsecured. Ever. I may eventually order a keyed SPST switch for some sort of safety, but I'm good without it for now.

What do you guys think? What wire is the "on" position for the ignition? Thanks in advance for any help.

If anyone was wondering, I have about 10-12 hours total into assembling, fabbing and installing. I could do it much faster now I know what the heck I'm doing.

- Z

 

[skooter65]

So I installed the All Balls roller bearing set into the R1 triples. The triples bolted up to my FZ6 frame without a single problem. The R1 stem was 1/4" longer, but after installing the All Balls lower bearing, it added just over a 1/4" to the overall length. The top nut goes on about 3/4 to full on.

I had to shave the R1 steering stops off and drill / tap new M8x1.25 holes. I have some bolts and solid spacers for my new stops. Works like a charm and set me back a whopping $4.06. I drilled / tapped new mounting holes for my headlight mount (VS-01 kit) and mounted it up. I used M8 bolts instead of the small ones included in the kit. It is much sturdier.

All the cables are routed, tire is mounted, everything is done except for one thing...

I have no mount for my ignition... and I cut the harness at the switch. I was thinking of doing one of two things...

1. Finding a new ignition and solder in to existing harness that I moved to the back of the bike

2. Run a SPST switch to bridge the power to the "on" position wire. I don't need the steering lock or even a key. I parked in my garage 100% of the time and we have secured covered parking at work. If I ride, I don't leave my bike outta sight or unsecured. Ever. I may eventually order a keyed SPST switch for some sort of safety, but I'm good without it for now.

What do you guys think? What wire is the "on" position for the ignition? Thanks in advance for any help.

If anyone was wondering, I have about 10-12 hours total into assembling, fabbing and installing. I could do it much faster now I know what the heck I'm doing.

- Z

This is a very promising thread to see; Could you possibly provide the part numbers for the All Balls bearing needed to convert.

As for the the ignition; I chose to go the RFID route when I did the fork conversion. The system I used was a bit pricey but it seems that there are a few cheaper alternatives out there. I have seen the unit in the link below installed on a few bikes; price is appealing and it seems to works well.

car engine push start button/RFID engine lock FS 55 ignition starter/keyless go system, push button engine start stop system-in Alarm Systems & Security from Automobiles & Motorcycles on Aliexpress.com


Another option is to relocate the stock ignition. I have an FZ1 conversion in process that I relocated the ignition to an open frame section on the RH side of the bike. I will snap a few photos when I get home tonight.

Thank you for the thread!

 

[mxgolf]

Wow quite a build. Can't wait for the finish. We need to get a Portland-Vancouver FZ6 ride going this coming spring. I like the Werks exhaust. Looks great but how does it sound? I have the FZ1 bars but really like the Renthal bars you are using. Keep us posted and I am sure you will. Thanks, :thumbup:

 

[PDX_Piggy]

Everything is done except the ignition. I pretty destroyed the stock ignition. I now have the five wires from the ignition. They are solid red, solid orange, solid brown and two smaller wires. I don't need any sort of security measures, just need the ignition to turn on and the fuel pump to prime. Any ideas? If all else fails, I'll end up buying another ignition.

Thanks!

 

[lrojasma]

Hi

Right now i am doing the same mod, can you help me with something?

Did you use R6 or R1 triple clamps? i ask because somewhere you say R6 and somewhere you said R1.

Wich one is it? and wichi year (if you have the part number would be nice)

And other question is.

The front axle, spacers and rims work ok with the new clamps? i mean the distance beteween forks is the same?

I ask becuse i already bought some FZ1 clamps, and i see it a little difficult to use because the lower clamp isn´t flat, so the new stopers would be a little difficult to put on, and i would like to use the upper R6 clamp for the steering lock (i would lose it with the FZ1 upper clamp).

thank you.

 

[PDX_Piggy]

Hi

Right now i am doing the same mod, can you help me with something?

Did you use R6 or R1 triple clamps? i ask because somewhere you say R6 and somewhere you said R1.

Wich one is it? and wichi year (if you have the part number would be nice)

And other question is.

The front axle, spacers and rims work ok with the new clamps? i mean the distance beteween forks is the same?

I ask becuse i already bought some FZ1 clamps, and i see it a little difficult to use because the lower clamp isn´t flat, so the new stopers would be a little difficult to put on, and i would like to use the upper R6 clamp for the steering lock (i would lose it with the FZ1 upper clamp).

thank you.

I used 07' R1 triples with an All Balls bearing set. Most modern sport bike suspensions have the same triple offset. If the triples work use them. Once you have a working set of triples, all you need is forks with matching rotors, brakes, wheel, axle and spacers. I'll post some new pictures when I get back from vacation.

- Z