KAWASAKI KH & S SERIES FORUM

cabbie · 3rd gear Joined: 14 May 2009 Posts: 232

Not sure if you guys want this project posted on the "S" series forum as it's a H2 special?

I'll start it but if you're not interested please say.

This is what I have so far:
Gary's drag bike H2 motor

A gsxr 400 frame and Aprilia swinger

Dymag alloy wheels

And here are the yokes I had made to order by "Billet Bike Bits"

garyb · Posted: Mon Sep 28, 2009 5:26 pm Post subject:

you keep it on here cabbie me likey

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Head Down Arse up

Soeren · Joined: 02 Sep 2008 Posts: 3 Location: Denmark

Hi
A other great build to look forward to

Sören

bubba2 · 2nd gear Joined: 03 May 2009 Posts: 97 Location: Dorset

Sweet bring it on..

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Back on three !!

scouse · Posted: Tue Sep 29, 2009 5:27 am Post subject:

looks like a cool project

good luck

Gary T
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Ride it like you stole it

cabbie · 3rd gear Joined: 14 May 2009 Posts: 232

Thought I'd make a start on the rolling chassis, there are two problems to get round:

1, the rear wheel is off a gsxr 1100 that uses a 20mm axle, the swing arm is off a YZF R6 that uses a 30mm axle, I'll need to make reducing bushes to fit the chain adjusters

2, the R6 swing arm is 25mm wider than the gsxr 400 frame, this will need a lot of fabrication, I intend to cut the pivot section off the R6 arm and weld on a gsxr 400 swing arm pivot section (I got a gsxr 400 swing arm with the frame)

The Kwaka 750 engine is a simple fit in the gsxr frame, just a few mounts to weld on.

cabbie · 3rd gear Joined: 14 May 2009 Posts: 232

Right, time to get this built.

I made the reducing bushes for the R6 swing arm

The forks are back from FireFox racing full rebuilt with Ohlins internals, re-valved and anodised etc etc

I got Brembo calipers, just need two adapter plates to mount the on.

Now I wasn't sure how to build this but I've thought for some time and decided to go with no light, no clocks or anything electrical, I got this box from the states to control the engine ignition etc so this is the wiring loom/harness

Looking good already, lol just need to get the swing arm in the frame then it easy from there.

BIG AL · Posted: Sat Nov 14, 2009 12:37 am Post subject:

looking good there cabbie, keep us update with more photos
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BIG AL
If All Else Fails (Hit it with a big hammer)

cabbie · 3rd gear Joined: 14 May 2009 Posts: 232

I've spent the last two weeks working out how to fit the R6 swing arm in to the GSXR 400 frame, it's a little more of a challenge than I first thought, this has to be done right or the end build could turn out a disaster!

The plan was to cut the pivot section off the R6 swing arm and weld on a pivot section from a gsxr 400 swing arm, this seamed the easiest option BUT would have caused chain clearance issues etc.

This is the R6 swing arm pivot spindle

The large threaded section is the same as the gsxr 400 frame thread so It'll screw in to the frame ok, what I'll do is machine 10mm off each side of the inner frame so the swinger fits in, the R6 spindle is too long so I'll cut the end off and re-thread inside the spindle and use a bolt instead of a nut, the other end of the spindle will be trimmed to sit just inside the frame recess, sounds complicated but it'll work well.

The only problem is removing the 10mm of alloy from inside the frame to slide the swing arm in as it'll have to be done by hand, I'll make up a jig so each side is cut true.

cabbie · 3rd gear Joined: 14 May 2009 Posts: 232

Had some free time for the bike today.

The front Dymag is made for a gsxr 1100 that uses a 20mm spindle/axle, unfortunately I'm using gsxr 400 forks that use a 17mm spindle/axle, so, here are the front wheel spacers and bearings

What I've done is made new spacers with a 17mm bores and change the right hand bearing from a 6204 to a 6303 (same size bearing except the ID measurement)

Here's the new parts fitted, I just need two outer spacers now to fit the wheel.

I also made a reducing spacer for the rear caliper holder

The new carbs arrived too, blood moosive they are, lol