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Taken a while, track bike anyone?

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Post  Martin F Mon May 16 2022, 18:16

Firstly I would just like to say how much I love these bikes and how invaluable a Haynes manual truly is.
I did not listen to anyone that told me it couldn’t be done and went on my own path (it was very long and windy with many dead ends).
The bike started out as a commuter that had been loved and very well serviced.
Taken a while, track bike anyone? 06dd2e10
Work then started on a mammoth restoration project.
Complete strip down and replacement of most moving parts including powder coating of frame, new shock, fork rebuild with new springs, you get the idea.
Taken a while, track bike anyone? 06dd2e10
After much time and money thrown at the bike it was done and looked not bad.


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Post  Martin F Mon May 16 2022, 18:19

Taken a while, track bike anyone? Ce628710
Start of the rebuild
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Post  Martin F Mon May 16 2022, 18:23

Taken a while, track bike anyone? 9a30f610
Bike getting towards the end (as I thought at the time) of the build.
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Post  Martin F Mon May 16 2022, 18:34

I finished the build and used the bike for a season of track days, going round the country to many different circuits.
I felt the bike was letting me down a bit, so decided on a new project for the winter.
Upgrading the engine to a 660cc stroker with ported head and high lift cam shaft.
I did quite a bit of research on this before undertaking such a build and it seemed quite easy.
Bottom half of a FZR600 with the top half of a YZF600r, making a much better more powerful and stronger engine.
How wrong I was. There are many things that the forums just don’t tell you, but I have learnt it all now (if anyone else fancies this conversion talk to me and I can explain some of the issues).
Taken a while, track bike anyone? 30ea2110
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Head looking lovely, skimmed, ported and cleaned with the valves re-seated.


Last edited by Martin F on Tue May 17 2022, 21:26; edited 1 time in total
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Post  Martin F Mon May 16 2022, 18:38

Taken a while, track bike anyone? 69049710
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Engine build nearing complete (or so I thought)
Hi lift cams installed with all clearances checked and adjusted (larger shims due to the cam shaft).
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Post  Martin F Mon May 16 2022, 18:47

Taken a while, track bike anyone? 47d7e710
Engine now in with new Dyna coils and cleaned, balanced and re-jetted carbs.
I was thinking nearly there now, but so much still to do.
This was when things started to really take some time.
Wanted to fit the YZF oil cooler (was suggested on one of the forums), but this was not a straight swap and needed some fairly major mods to the block.
The sprocket also doesn’t line up with the back wheel, so again bit of work required here.
Taken a while, track bike anyone? 6a258410
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Post  Martin F Mon May 16 2022, 18:50

Oh
I totally forgot
You have to change the loom and cdi unit as totally different.
Taken a while, track bike anyone? E5efbd10
Taken a while, track bike anyone? 54ced310
I then decided that an electronic dash with gear indicator would be good (just a bit more work)
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Post  Martin F Mon May 16 2022, 19:06

I also decided on race fairings to complete the look, which again turned out to be a bit more work than expected as had to fabricate something to actually sit on

Taken a while, track bike anyone? 2cb13f10
The bike is finished (wrong again)


Last edited by Martin F on Tue May 17 2022, 21:24; edited 1 time in total
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Post  Martin F Mon May 16 2022, 19:19

During the build I had installed an EBC race clutch set with supposedly “upgraded springs” 😂
I thought I would get the bike dyno tested before I went back on the track.
The bike sounded fantastic and flew up the revs. The problem was it went up the revs a bit too quick. The clutch was slipping which was very frustrating. After all this work the bike was no good, but another way of looking at it was I now had an engine that was producing more power than the clutch could handle.
The dyno test had got up to 90 at the back wheel (more than the stock YZF600R produced when first out of the factory 😃
The problem was getting a bigger clutch to fit.
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Post  Martin F Mon May 16 2022, 19:30

Reading on more forums the YZF600R clutch can be used.
I would just like to make it clear, it does fit but again there are some mods required to the block and the push rod.
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Post  Martin F Mon May 16 2022, 19:41

I installed a complete new clutch with plates, friction plates and springs. The YZF clutch is a bigger unit with more and larger springs.
The bike is now complete and rides really well, down a bit on speed but I think this is to do with incorrect sprocket 
Taken a while, track bike anyone? 37560c10Taken a while, track bike anyone? 9668ea10


Last edited by Martin F on Tue May 17 2022, 22:35; edited 2 times in total
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Post  Martin F Mon May 16 2022, 20:15

I am looking to go on one more track day with the bike (going to drop the rear sprocket a couple of teeth) but I will then be looking to sell the bike.
I have a massive spares package (engines, wheels etc etc)
If anyone fancies a new old toy give me a shout
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