My XS11 Project - Juggernaut

[fredintoon]

This project gives me a stiffy. Is that wrong?

Hi Davey,
only if your mommy catches you. Then you'll get a spanking. But you might enjoy that - - - ? Um, are we on the right list here?

[Mathh]

I asked mathH about the extended middle shaft he had made, but no reply (he's busy I see)
I see a way that the entire middle drive can be left intact and the end of the splined shaft cut down about 8-10mm and a 1-piece adapter made that goes between the factory middle drive and the middle drive gear located in the case. This would not require removing the 90* pinion gears and having to reset backlash/whatnot.

Hi Chop, sorry about that. Completely forgot about it. Can't help you though. Both the extended shaft and the 1-piece adapter have been made by people who no longer do this.. My 1-piece adapter however was laser cut abd did not need shortening of the splind shaft, but I can see why you do that..
cheers, Math

[xschop]

When I get to the shop later, I can check the insertion depth of the middle drive shaft on one I have torn down. Every one I have handled only inserts about half the machined spline length. With a 30mm spacer between middle drive and case, an extention would be the easier solution. If someone has ready access to inner and outter spline cutting equip. then these can be made without costing an arm and a leg. I can cut outter, but inner splinning is a deal breaker.

[CruisingRam]

Wow- amazing build! I am inspired! I am subscribing to this one. n

[MrFreeze5]

Im not sure on the MD, I havent really looked at it. I kind of hit a big road block recently though. Since Xmas Ive spent nearly $2000 on vet bills for my dog, so it put a temporary stay on things.

Right now Im still working on getting the swingarm aligned correctly. The manufacturing tolerances on a 30 year old bike are crap. Cross bars are crooked, stuff isnt perfectly aligned, etc. So I have to build a jig to make sure I get the front and rear wheels centered and on the same plane and make sure the frame is where it needs to be. The biggest problem I have is that the pivot points arent ligned. To keep the pivot axle from pointing at an odd angle and moving the entire swingarm, I have to use a ratchet strap and physically tweak things back into place. There's no evidence of a wreck on this frame, And I noticed I have the same problem on my parts frame, so I blame dated manufacturing. But its REALLY making things difficult given my current facilities.

From the looks of it, once I get the swingarm where it needs to be, if I use solid engine mounts, I wont have any Ujoint clearance issues. It looks like I just need to grind down the right side frame pivot point, not the left.

[apg0106]

any updates? pictures? I just bought the triples of an 04' busa, waiting for it in the mail. your bike is looking really good. cudos

[MrFreeze5]

any updates? pictures? I just bought the triples of an 04' busa, waiting for it in the mail. your bike is looking really good. cudos

My machinist got really backlogged lately, so he's pretty behind on my parts. On top of that, my dog has racked up significant vet bills since Xmas, so its put a real damper on the project. Not much to update right now really.

[tinman905]

Did you get around to making the jig to align the frame? Have you figured out if you are going with a middle drive spacer yet?

Im not sure on the MD, I havent really looked at it. I kind of hit a big road block recently though. Since Xmas Ive spent nearly $2000 on vet bills for my dog, so it put a temporary stay on things.

Right now Im still working on getting the swingarm aligned correctly. The manufacturing tolerances on a 30 year old bike are crap. Cross bars are crooked, stuff isnt perfectly aligned, etc. So I have to build a jig to make sure I get the front and rear wheels centered and on the same plane and make sure the frame is where it needs to be. The biggest problem I have is that the pivot points arent ligned. To keep the pivot axle from pointing at an odd angle and moving the entire swingarm, I have to use a ratchet strap and physically tweak things back into place. There's no evidence of a wreck on this frame, And I noticed I have the same problem on my parts frame, so I blame dated manufacturing. But its REALLY making things difficult given my current facilities.

From the looks of it, once I get the swingarm where it needs to be, if I use solid engine mounts, I wont have any Ujoint clearance issues. It looks like I just need to grind down the right side frame pivot point, not the left.

[MrFreeze5]

Did you get around to making the jig to align the frame? Have you figured out if you are going with a middle drive spacer yet?

Not yet. I was appalled when I went to go buy a new battery and charger for my 18v Dewalt circular saw that my old roommate stole. On top of that, the clutch springs broke in my FZR, and its 30mi away in a friends garage. So Ive been working on getting my Jeep back on the road. Unfortunately Juggy has suffered, although he's sitting in the living room right now, and I mess around with it when I can. Space is a real concern for me at the moment. But in the next month or so I will be moving to a house with a garage. A friend of mine is also buying a house with a HUGE shop and will let me use some of the space, so if I dont move, Ill have access to that. But until then I think this one is kinda stuck in limbo. But if I get shop access, I may be able to make a steel jig instead of wood. We'll see what presents itself.

I dont have a Busa front wheel yet. I bought one in Jan, but it ended up being bent. I have to have the front wheel before I make the jig anyway.

As for the middle drive spacer, i will probably need one, but I am not sure exactly how thick it needs to be just yet. From the looks of things, once I get the swingarm exactly where it needs to be, there should be plenty of Ujoint clearance at the frame without modification. I also plan on using solid engine mounts, so engine movement isnt much of a concern either.

Once I get this swingarm nonsense done, I need to go ahead and drop the engine in to check the fitment before I go any farther. Its pretty frustrating to be at a stand still like this though.

[bakerboy]

reminds me of college

Your pics are great and the bike looks great so far!

In college I built a Kawasaki 454LTD in the living room of my 500 sq. foot apartment....

[MrFreeze5]

I unfortunately have not made much progress on Juggy thanks to all my other vehicles deciding to hate me at once. But today I got some goodies in that Ive been waiting for. My slave cylinder mount and my upper triple.

Here's the salve cylinder mount. Its made from 5/16" aluminum and has fancy Ti bolts



Here's the triple. 7076 T6, accomodates up to a 1-5/8" drop of the tubes to raise the front end since the Busa forks are so short. I need to shave a little here and there for final fitment, but overall Im happy.

[TomRodgers]

OOOOOOOOOOOooooooooooooooooooohhhhhhhhhhhh......My avatar is getting excited!!!!!!!!!

[thewright1]

OOOOOOOOOOOooooooooooooooooooohhhhhhhhhhhh......My avatar is getting excited!!!!!!!!!

Tom, where on Earth did you find that avatar anyway??

[Coopz]

Tom, where on Earth did you find that avatar anyway??

On most forums at least one member is always using it

[81xsproject]

I unfortunately have not made much progress on Juggy thanks to all my other vehicles deciding to hate me at once. But today I got some goodies in that Ive been waiting for. My slave cylinder mount and my upper triple.

Here's the salve cylinder mount. Its made from 5/16" aluminum and has fancy Ti bolts

Hey, that looks familiar.