My XS11 Project - Juggernaut

[MrFreeze5]

Parts are finally starting to trickle in for the build, and I am trying to get as much done as I can in hopes of finishing before summer. So here is, the beggining of The Juggy.

The plan is a frame up budget build, but still custom and sporty. Then once its rideable, then I can really start polishing it up and making a nice final product.

2002 Hayabusa forks and monoshock
Dirt bars
2003 FJR1300 swingarm/final drive
79(I think) XS1100F tank
Hydraulic clutch conversion with Brembo radial MC
Dual stainless mufflers
Solid engine mounts
Possibly a Ducati 996/998 tail
7" round front headlight
Possibly a cafe fairing
More as I go.


'81 Titled frame (yes, its in my living room)



Untitled engine and electrical donor. Supposedly had a rebuild that wasnt paid for and it sat at the shop for a while. Has good compression all around, so Im going to check it out, but hope for the best. Needs carbs. The clutch cover is with my machinist getting fitted for a Ducati slave cylinder, since I already have spares of these for my FZR. I need the timing cover and flywheel covers though.






Ive got a whole bunch of parts showing up on monday, my Busa forks, tank, and I think the shock. And tues or wed my complete swingarm and exhaust will be here and then I can really get started.










More to come as I make progress. Comments? Suggestions?

[tarzan]

You must be a batchelor.

I wish I could build one in my front room.

[MrFreeze5]

I wish I could build one in my front room.

One of the advantages of being single, another is that I can afford parts The dog isnt a big fan though.

[Athedra]

Well you took the words right out of my mouth. Would love placing bones in my living room and work on her, but the wife would have the same reaction as your dog has.

What type of conversion are you doing on your yoke to fit the busa forks? Your swing arm look a tad wider. Did you make it wider for a wider rear tire or is it just the beer affecting my eyes there?.

Would love to see jugernaut when she / he is complete. The busa forks might be a way to go since you will be able to fit the busa ABS system while you are at it. Dont know if the rear disc will fit, but if you made the swing arm wider, you might be able to fit the busa rear wheel with a bit of conversion on the shaft side.

The carbs are fairly easy to find, problem we have over here is the intake rubbers. If possible, ask your engineering friend to make you a set of steel intakes and use Suzuki intake rubbers. They are just tubes. I don't know if the distance from carb to head will be a problem.

The other oprion is to get a set of intake manifolds made, and then using a TL1000S throttle body system. I had a look at converting my old set of carbs to throttle bodies with R1 injectors in there. Found the only usable injector and Fuel manager that works on the XS's is the T100 golf system. Problem is that over here it works out to just under R30 000 for the system since it is R4500 per injector and then you still need to get the Fuel manager and pick ups.

Good luck, and looking forward to some more pictures

[MrFreeze5]

For the rear wheel, I will be using the stock FJR1300 wheel for now, which runs a 180 or 190 tire. That will get the bike rolling, then I am planning on fitting a R1 wheel in place of the FJR wheel since the two have the same size cush drive. Plus the FJr wheel is a 3 spoke and a fairly close match to the busa front wheel. As for fitting the forks to the frame, its only a matter of a special bearing and a small spacer on the Busa stem since its a bit longer. I wont be bothering with an ABS setup, just conventional braking. Ill be using the stock busa 6 pots up front, and the FJR rotor and caliper. The caliper appears to be the same as early R1 calipers, and also comes with a brembo MC that looks like it might bolt up.

Fitting up the swingarm will require some considerable fabrication to the frame both for the pivot mount and a monoshock conversion. It will also need the middle drive spaced out 30mm or so for the driveline. But that comes later, first I need to finish the chassis fab, then Ill deal with the engine.

This bike is intended to be sporty, but more comfortable than my FZR so I can take longer trips in the moutains and not have my whole arm go numb. But it wont be a long-hauler I dont think. Just short weekend trips and such.

Ive strongly considered the FI swap, but thats not going to happen in this phase. I want to get it simlpy running well and rideable as soon as possible, and then make more upgrades as I go. I dont want this build to take 2.5 years like my last one.

[Athedra]

Please keep us (me) posted on this one. Would love to see how much lift the busa forks does on it, and might be a worth while conversion on my side as well.

[MrFreeze5]

It should actually lower the front end a bit. But since i dont have and never have had a set of XS11 forks, so i dont have a base for comparison. But Ill have some basic measurements in a few days.

[Athedra]

I'm sure someone on here will have a set of forks outside the frame and be able to measure it for you to give you a base figure. I am guesstimating that the busa forks will be longer, and might just give it a slicker look. Other possibility is that they are shorter, which might cause a problem on your back. might have to drop the rear on the mono shock to keep the look balanced.

[Schming]

Fork Length...

My stock 80G forks measure 31 7/16" From top of air cap to center of axle. HTH P.S. they are outta da bike

[Mathh]

I love these kind of projects! Nice swingarm as well This means a longer wheelbase as well for more stability and comfort on long sweeping roads, not that brilliant in hairpins however... maybe it will work out fine with the shorter forks.

[MrFreeze5]

I love these kind of projects! Nice swingarm as well This means a longer wheelbase as well for more stability and comfort on long sweeping roads, not that brilliant in hairpins however... maybe it will work out fine with the shorter forks.

Im not sure how long the busa forks are in relation to the FZR forks, Ill know that tomorrow, but I dont think theyre much shorter, if at all, and might actually net a higher ride height due to the forks being more suited to the greater weight. But needless to say, tuning the suspension in will take some time and finesse for sure. I dont need this bike to be the best handling thing around, and I do want performance out of it, but hopefully not compromising comfort too much since this will be my highway bike, but theyre mountain highways. If I want to play in the hairpins, Ill throw my FZR into the canyons and have all the handling I could want. but the FZR kills my wrists in short time. But it was built to have razor sharp handling, and not so much comfort.This should be much better for longer trips and Im actually planning the build around making it more highway friendly in the end. Things like tail options, (eventual) passenger seating, exhaust placement, and luggage(but removeable soft sport bags only). But the goal is to get it rideable first, then Ill start working on the highway accessories. I find it fun trying to balance everything in the build. Makes it interesting and original.

Im sure I will be bugging you quite a bit in the near future with questions about your setup, its given me a lot of motivation.

[MrFreeze5]

Well the R1 forks are about 29-1/4" from axle to cap and uses a 23-1/2" tire (120/70/17). I imagine the Busa specs are not too far off, and the tire is the same.

[jmnjrpa]

How's that swing arm and final drive work out? Will it bolt up to the xs frame or do you have to modify? How is the gear ratio? It is going to allow a wider tire, right? Project looks good!

[jmnjrpa]

Fly wheel cover

Have one for cost of shipping. It has a ding that will need weld or body filler. About 3/4" indention at bottom face. Will get pics if you want.

[MrFreeze5]

How's that swing arm and final drive work out? Will it bolt up to the xs frame or do you have to modify? How is the gear ratio? It is going to allow a wider tire, right? Project looks good!

The FJR swingarm has an open U joint instead of a tube covering it to the middle drive like the XS, so the pivot on the FJR swingarm is narrower since it does not reach the left side of the frame. So it will need a new mounting point fabricated to bolt the left side of the pivot to and still clear the ujoint. I also have to do a monoshock conversion on the frame. I forget the final gear ratio, but IIRC i think it was a bit higher than stock XS. It should allow up to a 190 tire or so. I plan on running Pirelli Diablo Stradas. 120/70/17 front and 190/50/17 rear.

Ill get back to you on that cover.