My XS11 Project - Juggernaut

[MrFreeze5]

If you can find a cost effective solution to the shaft extension, you will be over the hump on this swap.
Do you have pics, links to Math H's spacer?

My thoughts exactly.

Ill try to find the pics again. I got a virus and lost all my bookmarks and stuff 2 weeks ago. Ive got a picture of a spacer, but I am not sure if it is mathh's or not.

[MrFreeze5]

This is the only real pic of a spacer that I have found, but I do not remember who made it or for what project. I havent pulled the MD off my engine just yet to compare so Im not certain exactly what Im working with yet. Ill get to that part very soon.

[MrFreeze5]

Thanks to a few hours above freezing, I was able to get most of the snow off my patio and get some work done on the frame. I started by hacking off the old seat rails, battery box mounts, center stand mounts, and several other misc tabs and brackets that are in the way. I may still need to knock off a few more tabs here and there, and will probably have to add my own mounts for electrical bits onto the subframe later, but its a start.

[MrFreeze5]

Well, after doing some research, Im glad I decided on CF for the body. Apparently that indigo blue color is a bitch and a half to match.

My machinist let me know he got started on my hydraulic clutch slave plate. It should be ready soon, and he is shipping out my slave mount for my FZR next week. Ill be sending him my stock triple this week so he can start planning my custom replacement. I also need him to make a set of risers. I can only find 1" rise for 1-1/8" bars, and they only come in black. I want a 2" rise, and bare AL finish to match the rest of the front end.

Things are moving along nicely. Once I can get all this custom machining out of the way, then I can really get moving on this project.

[Mathh]

I finally had some time left to look for a couple of pics I promised you. Here they are. Keep up the good work.. too quite here











Here the home made longer shaft next to the welded and (later) broken shaft. They are lengthened in the middle because I glued the MD and the spacer together (spacer has outer bearing).





this is my first attempt: an adapter welded from bits and pieces, turned out to be too long. Later I had a new shorter one lasercut. Turned out nice.

[MrFreeze5]

Thanks for the pics. It looks like your swingarm is unmodified, and I am seeing the same thing on mine. I found an easy way to use the FJR pivot axle with minimal machine work. Once I get it back from my machinist Ill be ready to weld everything in. This swingarm fits right into the frame nice and centered, its just the issue of being wider to the left to deal with.

You look like you have more room between the ujoint and the frame than I do and I am wondering how.My Ujoint cant operate as it is now, it looks like I need to notch my frame.



Alrighty then! Update. I have had some computer issues the last few days, and once again moved the bike, but I have made some progress nonetheless. I now have Juggy and the parts bike side by side in the basement so I can determine where I want all the electrical to go on the frame. Ive got a stock upper triple on the way to my machinist so he can make my upper triple. My headers came in. Theyre not pretty, but theyre straight and true. Plus I will need to get my midpipes chromed anyway, so I am planning on having it all done at once. I have 50' of black header wrap, but I dont think it would look right on this bike.



I stuck a set of bars on it just for ****s and giggles. It Busa clip ons and I plan on running high, fat dirt bars for sure, but it gives me an idea of where things will be. Just for fun I thought to throw on my brembo clutch MC that I have waiting to go on my FZR and I love it. It has a grey CRG lever that I didnt want to use on my FZR, now I know where its going. So in the interest of the buildoff, I am appropriating this Brembo radial cluch MC with CRG lever for the buildoff. I also found the perfect piece of steel braided hose with AN fittings on both ends in my parts bin and just happened to have a banjo fitting for it. It will work perfectly for the hydro clutch to go right under the tank and then use a hard line to the engine. Its nice being a packrat for good parts



I also got my hands on a Nissin radial brake MC. Its a 3/4" from a 05/06 Kawi 636 and will fit the Busa 6 piston calipers nicely. And the best part was the price! $25 shipped! I have started stripping it to see how its natural color is. if its not shiny enough, I will paint it to try and match the finish of the clutch MC. I will be repainting the lever, or actually probably powdercoating. I pulled the back clamp from my Ducati clutch MC that has a threaded mount for a mirror and it fits the Nissin MC fine, so thats my right mirror mount. Now I need to get one more threaded clamp for the other side, Ive seen them on ebay.



My swingarm pivot axle is getting reworked. I have to have a small bit turned down and threaded. Otherwise it doesnt require much modification thankfully enough. Once I have that done, I can finish the left pivot mount. I am hoping to have a copmleted rolling chassis by the end of the month. I think I can accomplish that. Once thats done, most of the hard stuff is behind me.

[Mathh]

You look like you have more room between the ujoint and the frame than I do and I am wondering how.My Ujoint cant operate as it is now, it looks like I need to notch my frame.

yup, i did a LOT of grinding on the inner left side of the frame.
Looking good, will work out just fine!

[MrFreeze5]

yup, i did a LOT of grinding on the inner left side of the frame.
Looking good, will work out just fine!

Ok good, that makes me feel better

[tinman905]

This is the only real pic of a spacer that I have found, but I do not remember who made it or for what project. I havent pulled the MD off my engine just yet to compare so Im not certain exactly what Im working with yet. Ill get to that part very soon.

You have peeked my interest in this FJ1300 drive swap and I was wondering have you found out if that spacer is going to work if so where did you acquire it. Do you know as of yet if you will have to extend your middle drive shaft? Excellent posts on your project good pictures also I look forward to the end result.

[MrFreeze5]

You have peeked my interest in this FJ1300 drive swap and I was wondering have you found out if that spacer is going to work if so where did you acquire it. Do you know as of yet if you will have to extend your middle drive shaft? Excellent posts on your project good pictures also I look forward to the end result.

Well, thats not my spacer, thats just a pic I found of one that has been made before. From what I understand from reviewing Mathh's previous posts and info on his bike, the spacer was 30mm, and the middle drive input shaft had to be spaced accordingly. I am planning on having a whole new shaft machined as well as the spacer plate. I will start on that phase once I have my rolling chassis completed, which is moving along steadily, if slowly. Just this morning I purchased a FJR rear wheel with a Dunlop D208 tire, and I as bidding on a Busa front wheel and Dunlop tire from the same seller. It has another day or two left. The FJR wheel needs a repaint, and the tire will need to be swapped eventually, but it still has some miles in it, so it should do fine for the build, then this summer, I am replacing the tires with Pirellis.



So far, the entire rear end swap has only cost me about $450, and that will include having the swingarm fully mounted in the frame. But the extra machining on top of that for the middle drive will be at least as much if not more unless I get really lucky.

I also bought my bars. Renthal fat bars-titanium finish, and I have a set of Driven billet risers on the way for them. The risers will be going to my machinist, along with the Busa upper triple today. Once he gets the upper triple he can really get started. My upper triple will have a place to mount the risers and will be slightly offset so that the forks can sit lower than stock to compensate for the large difference in fork length.

[MrFreeze5]

I had an interesting change in the build schedule today. As I mentioned before, I bought a stock upper triple to go to my machinist for dimensions for my custom upper. I was trying to come up with a use for it when he was done with it and I decided to have him mill out the clamp when he's done with it and I can use them for headlight clamps or whatever. That led me to the headlight mounting setup. Its the first time I really thought about it. I had just planned on making clamps or using those rubber grommet P clamps. But then I got to thinking about mounting signals and the fairing I want to run around the 7" headlight. Since most everything I am using for the headlight area is from a Ducati Monster, I checked out the bracketry involved and liked what I saw. I was originally planning on getting the headlight and fairing and all that later on, but since this setup bolts to the triple(from what I can tell, I need to see a S4r in person again), I needed to go ahead and figure out where it needs to be so the triple can be machined to accept the stock monster headlight mount. So in the interest of doing it right the first time, I went ahead and ordered all my headlight and front end ****. This will also really clean up the front end since there will be no need for any clamps on the fork tubes aside from the triple clamps

On the way we have:

Ducati Monster headlight bracket(the signal tabs are on the wrong way, they go out, not in)



Ducati Monster S4r Carbon Fiber fairing



While shopping for a headlight, I was snooping around on ebay and ran across a bunch of Delkevic stuff. It looks pretty nice, and the price seems pretty good too. And theyve got all sorts of ****, bodywork(bleh), lights, exhaust, and what seems to be a pretty nice OEM replacement wheel for the busa($only $160 new) and some other Suzis and hondas. I did a little research and the company is pretty big in the UK, but guess what- The US branch/store is like 5 minutes from my house and the weather is going to be nice again today, so I am going to ride my happy ass over there, take a look at the goods, and pick up this headlight:



And I already have a nice set of signals in my parts bin that should work nicely! So now all i need for the front end is a windscreen and a gauge! I am thinking a clear screen is the way to go, but smoked might look better depending on what I choose for guages

[MrFreeze5]

esterday when I went to pick up my headlight from the distributor, I was taking a look around at the big ass shop next door that they do their retail sales out of. This place is a giant salvage yard, used parts operation, used bike sales, and retail shop. And theyve got lots of odds and ends on had. I cant believe Ive never been to this place before. But anyway, to the point. While I was there, I found a set of risers that I liked that should work nicely and they were cheaper than on the internet, so I was happy. Then this morning my bars came in. I REALLY like the bar. I think it will look great with the fairing and it feels prety damn comfy. I mocked it up with the top clamp cover for the busa, but its kinda slanted and wonky. The final position will have the risers more upright, but I like the bars swept back just a little due to the really long ass tank on this beast.

I have been thinking about colors. I have decided to do the triples in black, the bar is a titanium color(matches the lower fork legs perfectly). I am thinking that I want to go with black MCs now instead of silver. And black controls and at least mostly black grips. I think it will provide the right amount of contrast, and also help break up the different shades of silver.

[motoman]

Interesting build..........and the Indigo blue has a perfect match if your wanting that color. It's a 2002 Toyota color. Can give you the code if your interested.

[MrFreeze5]

Interesting build..........and the Indigo blue has a perfect match if your wanting that color. It's a 2002 Toyota color. Can give you the code if your interested.

Yeah, if youve got it Id love to have it. Although I am going to run carbon fiber for everything but the tank, I plan on picking up a stock Duc tail to use when I want to put my soft bags on so I dont scuff my CF. Id like to color match it if possible. Ive also entertained the idea of a racing stripe

[MrFreeze5]

My pivot axle came in today and it fits like a freakin charm! I sent my machinist the stock FJR pivot axle and the stock XS11 swingarm pivot stud. The stock pivot studs thread into the frame through the stock swingarm. I had him turn down a portion of the large end that has huge threads on it. He turned it down and rethread to M22x1.5 to match the frame. So now the axle threads into the frame and will support the weight of the swingarm while I make the other mount.





Now that this part is done, I can start fabbing the other pivot mount. That will consist of a heavily gusseted piece of probably 1/4" plate, threaded through to match the thread on the end of the axle(m18x1.5), and will then get the nut on the other side of the plate.





I also had a bunch of other parts come in today. My headlight mount is here, another triple tree, my rear wheel with tire. The headlight mount should work out nicely and I should be able to mount it to the triples without much difficulty.

The wheel will need to be cleaned up and repainted, and a new tire eventually, but this one still has some miles left on it, so it will serve the purpose until I can buy a new matched set. Its a 180 dunlop now, I will be running a 190 Pirelli in the end.