Project K4 Gixxer

[wackyrider]

Well, I've done it. Gone to the dark side. I've bought myself a K4 gixxer (albeit with a damaged motor) but all the rest seems to be in good condition so I will be selling off some bits and pieces. 80's Freak has already put dibs on the complete subframe & tail section

Time for some piccies now.

My toys parked in the shed
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000426.jpg

The Gixxer
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000420.jpg

http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000421.jpg

Fairing & other parts
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000423.jpg

http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000422.jpg

And the MV brutale tail I bought off TK.
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000424.jpg

This is gonna be a bit of a slow build, thinking of 6 to 12 months to complete as I want to be able to do it properly, unlike when I was building the R1 having to put it back together just to go for a ride.

So it begins.....................

[RevHead]

Jules what was wrong with the motor ,big end problem chewing out the crank ,

[wackyrider]

Yep, the old owner took into the bike shop saying that the engine was making a bit of noise. Turns out the engine didn't like running with 1 litre of oil. Go figure.

[RevHead]

oohhh ,wow il keep an eye open for a crank for you Jules

[wackyrider]

I'm curious to see if a crank from a different year Gixxer will fit. Where's Gitzy when you need him with all his comparison websites and stuff

[Redmohawk]

Can the original crank be offset ground enough to fix it, or is it Fubar ? Room for a mini stroker in the block ? Just saying while its apart is it an option instead of going back to stock ? I'm just shooting idea's in the air , dont even know if you can get oversize bearings to suit etc.

[xa-mont]

according to part numbers, only 03-04 for the crank.
http://www.ronayers.com/WhereUsed/N/9935/PartNumber/12000-40830

[hooligan]

busa motor!

[xa-mont]

now that's a plan! lets squeeze a busa donk in there!

[wackyrider]

Actually, what year was Pete's Gixxer?

[RevHead]

94,they were the same from 93 to 98,that would be a great thing, better chassis with an 1100w donk init ,
http://www.ebay.com.au/itm/160751156376?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649#ht_500wt_949

[kiwi kdx]

TTTTTTurbo Bussa?

[LKC73]

Nice buy Jules. I would look at efi busa engine. 1100w would be interesting but why go backwards? Look forward, efi, decent snail hanging off the the engine, kicked up tail, mask head light the whole nine yards matey! You know you want to :cool:

[hooligan]

94,they were the same from 93 to 98,that would be a great thing, better chassis with an 1100w donk init ,
http://www.ebay.com.au/itm/160751156376?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649#ht_500wt_949

I think he's asking bout pete's (nakedturbobusa) T7/13, not yours, pete.

would have been a k series 750, but no idea which year.

[oldskool]

The busa motor does not just slot in, if you read Pete's build thread there was alot of chopping involved.
And not your build thread Proctor.

[wackyrider]

I dount I would go Busa motor anyway. First thing is to see what condition this motor is in. I'm gonna be looking for a K3 / K4 subframe which has been damaged as I need one to hack-up to be able to fit the MV tail

[Redmohawk]

4mm kit using your slugs (and you provide a crank) $2k includes a welded crank (yours) carillo rods and if your keen on more for about another $1k a 1070 cc set of slugs n rebore will give you 1143cc stroker for about $3k plus rebore cost. Have the counter balalance weights removed and crank lightened. Then hold on.

http://gsxrzone.com/cranks.html

[oldskool]

I dount I would go Busa motor anyway. First thing is to see what condition this motor is in. I'm gonna be looking for a K3 / K4 subframe which has been damaged as I need one to hack-up to be able to fit the MV tail

Why not just fab your own its what its all about.

[wackyrider]

Why not just fab your own its what its all about.

I already have the MV sub-frame, however the Gixxer sub-frame actually holds up the tank. It makes more sense and would also look nicer if I used the gixxer sub-frame and then modified it to accept the MV subframe onto it.

[Large]

The busa motor does not just slot in, if you read Pete's build thread there was alot of chopping involved.
And not your build thread Proctor.

Pete's is a 750

[oldskool]

Pete's is a 750
http://www.streetfighters.com.au/images/misc/quote_icon.png Originally Posted by RevHeadPete http://www.streetfighters.com.au/images/buttons/viewpost-right.png (http://www.streetfighters.com.au/forum/showthread.php?p=353098#post353098)
94,they were the same from 93 to 98,that would be a great thing, better chassis with an 1100w donk init ,
http://www.ebay.com.au/itm/160751156...9#ht_500wt_949 (http://www.ebay.com.au/itm/160751156376?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649#ht_500wt_949)
I think he's asking bout pete's (nakedturbobusa) T7/13, not yours, pete.

would have been a k series 750, but no idea which year.


Yes this was covered, relax Richard it isn't a Proctor hunt big fella.

[K6Thou]

Always liked the k4 shape. I'll be watching this one closely.

[Redmohawk]

Whats the spacing between header pipes/exhaust diam on your K4 headers at the head wacky ? I'm thinking Ti exhast would be nice for the gimp. I know the barrel/head angle is different with the rf donk to the K4, I did a bit of cut n shut on a Ti exhaust thursday was easyer that I thought it would be (sort of like a cross between welding Ali and stainless). Just trying to sus if its a easy swap k4 ti to rf600 .

[kiwi kdx]

bit pricey, but.......

http://www.ebay.com.au/itm/Suzuki-GSXR-1000-2003-model-DAMAGED-bike-still-starts-and-runs-great-/280850724273?pt=AU_Motorcycles&hash=item416401f5b1 (http://www.ebay.com.au/itm/Suzuki-GSXR-1000-2003-model-DAMAGED-bike-still-starts-and-runs-great-/280850724273?pt=AU_Motorcycles&hash=item416401f5b1)

[RevHead]

http://www.ebay.com.au/itm/2005-2006-05-06-suzuki-gsxr-1000-gsxr-1000-crankshaft-crank-shaft-/270920896160?pt=Motorcycles_Parts_Accessories&hash=item3f1424cea0#ht_557wt_93

[xa-mont]

Hey jules, i was just looking around today, and i think a 600/750 subframe will work for you too. from what i can gather the mount points are the same.

[wackyrider]

Sorry been a bit quiet lately. Mum's got a bit worse lately and back into hospital, So flew back home to spend some time with her.

Red, I will have to check for you once I get back.

Trav, cheers mate

[yoda]

Sorry to hear mate. Give me a yell when you get back.

If you need any plastic bits let me know, i have all the stuff off my racebike somewhere

[wackyrider]

Jon, cheers mate. I'll be selling most of the plastics from it. Only keeping the tank and maybe the front guard. I'm looking for a bent subframe that I can chop up to fit the MV subframe I have

[geesexar]

sorry to hear about your mum jules hope shes ok...the mv tail should look good mate

[Redmohawk]

All good mate , look after mum.

[wackyrider]

Righto boys, I need some info if any of you know. Looking for the below for my K4 Gixxer:

Centre to centre distance of the conrods
Compression height of the piston (centre of gudgeon pin to top of piston)
Diameter of piston
Stroke length

[xa-mont]

Centre to centre distance of the conrods
Compression height of the piston (centre of gudgeon pin to top of piston)
Diameter of piston : 73.0 mm
Stroke length: 59.0 mm
sdfasdfasdfsf

[wackyrider]

cheers Trav

[Redmohawk]

http://www.aperaceparts.com/tech/2008suzukigsxr1000.html (http://www.aperaceparts.com/tech/2008suzukigsxr1000.html)

111.8mm rod length centre to centre

[wackyrider]

Cheers guys. Any idea on the Compression height of the piston (centre of gudgeon pin to top of piston)??

[80s freak]

I should have your motor apart tomorrow Jules, then you can have all the measurements you like.

[Redmohawk]

While you have the verniers out old boy , exaust ports centre to centre would be tops ! There prob 80 - 80 - 80

And I have a set of headers winging there way from the good old USofA but it would be nice to know how much I gota mess with the titanium before it gets here.

[achtung]

The 05-06 gsxr 1000 engine will fit in your bike, few people on the gixxer forums have done this conversion.

[K6Thou]

Hey Jules you sorted the engine yet ?


This may help...... http://www.ebay.com.au/itm/gsxr1000-motor-gsxr-gsx-gsx-r-cheap-must-go-/261074204926?pt=AU_Motorcycles&hash=item3cc93c38fe#ht_500wt_1208

[wackyrider]

Engine is all good. Hope to be able to re-build it in a few weeks. Crank turned out to be ok so no damage there. Not gonna be able to go for the racing cams due to having to spend money on some other stuff for now.

Need to get a new set of rings and gaskets, maybe a couple of billet casing and slap her together.

Also just removed the top clamp and starting to draw up my new ones. This will be my first time making triples, so not sure what tolerances to use.

[K6Thou]

I reckon +/- 0 would be a good start as far as tolerances go mate. lol

[wackyrider]

Guys, this is the 1st draft of the top clamp. Can I get some feedback. Still undecided where to place the pinch bolts. And unsure whether to place the V-cut in the top clamp as well (I will be doing it in the bottom clamp)

20892090

[wackyrider]

What would you suggest as the minimum wall thickness for the clamping area around the forks?

What size of Socket head Cap screws to use for pinch bolts? I'm thinking 8mm

[xa-mont]

i would think 6mm bolts would be fine if you're using 3 or 4 of them. but that's just a guess.

And for thickness couldn't you just go off what the stock one is?

[wackyrider]

Just bought a set of billet engine casings for the Gixxer. Worth the price I think :)

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=280895601684

[latheboy]

Also just removed the top clamp and starting to draw up my new ones. This will be my first time making triples, so not sure what tolerances to use.

h6 would be the tolerance i'd go for, 30mm to 50mm is +0.00, -0.016

What program are you using to model in?
SW has "Simulation Xpress" I use it alot to bend the shit out of parts and find where it is going to fail.

M6 should be ok but it's easy to have a loose one in the group when there's alot of them. Look out the strenghts and strains of M6 12.9's V's M8 12.9's

[wackyrider]

Ivan, I've never used SW. I learnt on Autodesk Inventor, do you reckon SW is better? I don't believe that there is any simulation mode in the Inventor though. Not to my knowledge at least.

[latheboy]

I've never used Inventor so I can't say which is better.

I just did a quick sim on a rough clamp I modeled up, bendy...
You can change materials, mod the part in the sim and stuff to find the best option for strenght etc.

http://i1226.photobucket.com/albums/ee405/latheboy179/Clampsim.jpg

[Redmohawk]

Ivan Does SW have carbonfiber or plastics like polycarbonate listed in its materials data ?

[latheboy]

Yes to both Red.

[Redmohawk]

whats it go for ? worth the cash for a hack or is sticking with freeware a better option ?

[xa-mont]

its free like everything else on the illegal download sites

[wackyrider]

I believe Trav managed to download his. In which case I might have a look and give it a go too.

[wackyrider]

Not much been happening in the shed as I've just recently had knee reconstructive surgery. In the meanwhile been collecting some small goodies that I am waiting to arrive at the moment.

This week also need to collect my cyl head and gonna get it port & polished and might have a look at the crankshaft too.

Next week I will try and start working on fitting the MV sub-frame. I want to keep the front end of the original sub-frame as it contours with the tank well. Time to pull my finger out and start getting some work done

[xa-mont]

Yeah pull your finger out and get it ready for nfr

[wackyrider]

I could have it on the road for NFR, but I don't know if it will be how I want it by then.

hmmmm, decisions, decisions

[xa-mont]

nah take your time and just ride the R1 at NFR... take the Gix to the drags :P

[wackyrider]

Well, had a shit day today so I needed to head to the shed. Did some work on the R1 first, then headed for the Gixxer.

The sub-frame has been annoying me, so decided to have a crack at it.

Marked-up the old sub-frame
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000668Medium.jpg

The hacked the hell out of it
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000669Medium.jpg

What is left...
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000670Medium.jpg

Rough mock-up of the MV subframe on the bike. It will actually move about an inch further forward or so
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000671Medium.jpg

http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000672Medium.jpg

[xa-mont]

aint nothing like progress! that tail is going to look mega sick when it's done.

[wackyrider]

Might be able to use 2 of the current holes for the top mounts. Just need to make some spacers and line them up. For the bottom I will see when the top mounts are done.

Both top and bottom mounts fit on the inside of the original sub-frame.

[Gix11]

Interesting combo mate. I like it.

[nick76]

Its good to see something different!
I reckon it'll come up good!

[wackyrider]

Been colloecting a few parts slowly for the build.

Billet engine casings
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000673Medium.jpg

Samco hose kit
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000676Medium.jpg

billet steering damper bracket
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000675Medium.jpg

Stainless Bolt kit
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000674Medium.jpg

Leo Vinci GP Por muffler
http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/P1000677Medium.jpg

[FIGHTERMC]

here mine with the top mounts fitted,shaped the ones that were already there and drilled and taped for bigger holes.
http://i1128.photobucket.com/albums/m491/fightermc/gsxr001.jpg

http://i1128.photobucket.com/albums/m491/fightermc/gsxr002.jpg

will be fitting the bottom lugs during the week.

[nick76]

^^^Thats nice FIGHTERMC. Is that a Desmosedici seat unit?

[FIGHTERMC]

i'm not that up on ducati's mate.
guy down the road from me was braking
a 749 and i got the hole lot as you see in the pic for 250 euro.

[wackyrider]

I'm thinking of widening the top mount and using that one directly as the MV subframe is narrower than the Gixxer one. I'll just machine up a set of spacers and line it up.

[wackyrider]

Well, it was good to get back in the shed again. Had to do some work on my R1, so got the tank re-clear coated as I wasn't happy with the finish of it. I've also removed the subframe off the Gixxer and I am lining it up with the MV sub-frame. Gonna draw up some alloy spacers to be able to line up the top mount and then cut and gring to fit as well as order some stepped bolts to bolt up the top mount.
Once that is done I will cut off the bottom mount and machine up a spigot to slot into the round tube of the MV sub-frame and bend up some new tubing to join it to the Gixxer sub-frame.
I'll upload some pics soon to explain what I mean

[wackyrider]

Been a bit slack lately. Finally got the welder to weld on the spacer plate that I made for the upper mount of the subframe. Then drilled the hole out to an M8 and lined up the top mount. I'm gonna have to cut down the tie rod ends as they are gonna have to be shorter than I thought, but that's an easy one.

292529202921292229232924

[wackyrider]

In the meanwhile I've also had the head reco'd. Valve stems and seats have been re-machined, head has been acid dipped and new stem seals fitted.

292629272928

[wackyrider]

Starting putting the engine back together today. Big thanks to 80's Freak for his shed and valuable time

http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash3/74713_449006901823769_1035142991_n.jpg

http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash3/75936_449006905157102_1742646425_n.jpg

http://sphotos-h.ak.fbcdn.net/hphotos-ak-prn1/59353_449006981823761_916752444_n.jpg



http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash3/148224_449007025157090_489593078_n.jpg

[wackyrider]

Ok, looking for some peoples opinions here for a headlight choice. Looking at getting one of these two:

http://i.ebayimg.com/01/!B--HrQ!CGk~$(KGrHqZ,!jYEzKEH,tV)BM-P8iP3W!~~_12.JPG

http://i.ebayimg.com/09/!Bs7clsgEWk~$(KGrHqIOKkIEvOEh1-4hBL5zeNs9yw~~_12.JPG

[BANDITROD]

i like the top one jules i havent seen it used much

[wackyrider]

This is what the bike is looking like right now

31153116

[wackyrider]

Yeah Rod, I've been thinking about the top one for a while now, but I like the other one as well. hmmm

[BANDITROD]

flip a coin

[wackyrider]

flip a coin

i'd be lost without your wisdom........:cool:

[BANDITROD]

hehehehe i know

[rod185651]

http://i.ebayimg.com/09/!Bs7clsgEWk~$(KGrHqIOKkIEvOEh1-4hBL5zeNs9yw~~_12.JPG


I think the lines on this headlight matches the lines of the tail better. Where as the other headlight's lines seem sharper?


Dhttp://www.streetfighters.com.au/attachment.php?attachmentid=3116&d=1355266373 (http://www.streetfighters.com.au/attachment.php?attachmentid=3116&d=1355266373)

[wackyrider]

Yeah, that's what's pulling me towards this light, even though I like the other more. This seems to go with the bike more and it's cheaper too :D

[scotty]

here's some frenchy, might be a bit hexxy for ya but nooooice(can't reply in your wanted thread) http://bikecraft.net.au/c/51/risers

[wackyrider]

Still contemplating on which speedo to go for for the Gixxer. Looking at either the Motoscope pro
3142


Or the motoscope Mini
3144

[xa-mont]

Because you actually ride your bike i'de go the pro.

[BANDITROD]

i have the old version of the pro and its a great dash jules

[wackyrider]

Yeah, I'm thinking more the pro as it's a bit of a larger unit and the tacho is easier to read as well

[xa-mont]

the mini's look awesome, but just too hard to read when you actually want to (check speed when you see a speed camera)

[K6Thou]

Jules you need this....

http://www.ebay.com.au/itm/GSXR-1000-03-04-turbo-kit-/160942545490?pt=AU_Motorcycle_Parts_Accessories&hash=item2578ec5a52&_uhb=1#ht_500wt_1378

[Mishdog20]

Yes, yes he does...

[wackyrider]

No, no I don't. lol

As much as I'd love to.... I can't afford it

[xa-mont]

Puss

[wackyrider]

I'll buy it for you as a Christmas present as I am a great friend

Cheers Trav. That would be awesome

[xa-mont]

yeah... the poor dude who is sturgling to scrape together 480 to pay his own bike rego is going to get you a turbo kit.

[wackyrider]

New h/light just arrived. Had to see how it looks in place

http://sphotos-b.ak.fbcdn.net/hphotos-ak-ash3/75020_10152394429340165_289172118_n.jpg

http://sphotos-f.ak.fbcdn.net/hphotos-ak-prn1/536141_10152394429615165_1748018894_n.jpg

[Yella]

I like that, very nice. if ya change ay mind on it let me know :) the 7 needs a new lighting set up

[wackyrider]

haha, Cheers Yella :D

[wackyrider]

So finally got to get more work done on the sub-frame. Ordered some 6060 Alumunium 20mm square bar and cut it to size. Due to the reservoir on the rear shock i had to space out the lower mount by 20mm and then cut and welded a length of bar from side to side.

http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/Melbourne-20130122-00631_zpsa670463f.jpg

http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/Melbourne-20130122-00632_zpsec0eceb4.jpg

Then attached the tie rod ends to the MV lower mount and marked up and drilled the lower bar.

http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/Melbourne-20130123-00655_zpsedcae9bf.jpg

http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/Melbourne-20130123-00656_zpsb71a9e70.jpg

http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/Melbourne-20130123-00658_zps2874a2e3.jpg

Still need to clean it up and radius the edges then paint it. Will try to put it on the bike tomorrow to check the seat height and adjust as required.

[wackyrider]

Also, just collected my engine from Geoff after the rebuild, you're a champ mate. Need to take it to work with me tomorrow so I can de-grease and paint strip, then rub back and prepare for paint.

http://i770.photobucket.com/albums/xx348/wackyrider/Gixxer/IMG-20130123-00654_zpse55b5b06.jpg

[wackyrider]

Time to get this engine looking all purdy and stuff, so here we go.

Slung the engine from the overhead crane at work (handy to have :D)

http://i770.photobucket.com/albums/xx348/wackyrider/Melbourne-20130124-00660_zps6e727d36.jpg

and had a friend come over to give me a hand. So we started masking up the engine

http://i770.photobucket.com/albums/xx348/wackyrider/Melbourne-20130124-00659_zps90f8072c.jpg

Then got ye old faithful Paint Stripper

http://i770.photobucket.com/albums/xx348/wackyrider/Melbourne-20130124-00664_zps4cd2e27d.jpg

and started applying liberally. As you can see some of the engine had some crappy red paint on it as well

http://i770.photobucket.com/albums/xx348/wackyrider/Melbourne-20130124-00661_zps3b9efb37.jpg

http://i770.photobucket.com/albums/xx348/wackyrider/Melbourne-20130124-00663_zpsce1d8e39.jpg

then let the paint stripper do it's thing and gave it a clean in the parts washer. Ended up giving it two coats of paint stripper and two good cleans to de-grease and remove all the paint stripper.

http://i770.photobucket.com/albums/xx348/wackyrider/Melbourne-20130124-00665_zps2544c4a4.jpg

We the rubbed back lightly with some emry paper and started laying on some black goodness

http://i770.photobucket.com/albums/xx348/wackyrider/Melbourne-20130124-00667_zpsfaff3cf1.jpg

Getting there. I actually ran out of paint and need to get some more as it needs another coat of paint, but it's looking good :D

http://i770.photobucket.com/albums/xx348/wackyrider/Melbourne-20130124-00668_zps2bacf100.jpg

[FIGHTERMC]

turning out good mate.