luigi

Hi to all.

New parts arrived. Details, but necessary to finish the work anyay. Newcomers are the light alloy upper rear shock bracket and the spacer for the 520 chain sprockets.

The final bike height is the same than the old version in steel.

The threaded rod have a pitch of 1 mm, so for a turn of the bolt the height bike will be changed of 1 mm.

Attacco Ohlins anticorodal 03 Sept10.jpg

The little hole is a seat for a elastic pin that, with the Loctite lock firmly the threaded rod .

Attacco Ohlins anticorodal 01 Sept10.jpg

Here the new and the old bracket compared

Attacco Ohlins anticorodal 05 Sept10.jpg

Spacers give the correct chain allignment after the installation of the 520 series chain instead the common 530.

On the left the spacer for the sprocket (5mm thickness), on the right the spacer for the rear gear (2mm thickness).

The first was made on lathe, the second with laser cut.

Distanziali pignone e corona da 520 Sept10.jpg

This is sprocket spacer installed (bolt not tightened)...

Distanziale pignone da 520 01 Sept10.jpg

..and this is for the rear gear.

Distanziale corona da 520 03 Sept10.jpg

It's all for now, Ciao, Luigi.

Hi.

This is the crankcase width.

I've took the measures from a MY 2000 model engine that i'm sure that fit on the 1998 5th gen model frame and swingarm.

All quotes are in millimeters.

Ciao, Luigi.

Larghezza motore VFR.jpg

Hello.

Mod calls mod, so i'm thinking about an anti-hopping clutch. :ohmy: :ohmy: :ohmy:

Since i'm excluding a "ready to fit" kit in commerce, someone have never heard a modification that can turn possible a fitting on the 5th gen? :laughing6-hehe:

ciao, Luigi.

If anyone has a 5th gen motor lying around and could measure the width of the engine case where the swing arm pivots I'd greatly appreciate it!

Hi

Where the rear swingarm is hinged? I've understood right?

If you can wait 'til the next week i can tell you.

Ciao, Luigi.

This might be a silly ? but do the european cdi's for a 3rd or fth gen vfr have more hp then the us cdi's thanks

Hi.

Since the 3rd gen is not fuel injected, the only factor contolled by CDI is the spark advance, if the two CDI's works in different ways this can rule in some way the power delivery but:

1 - a modified spark advance changes, maybe just a little but changes, the exhaust emissions, and in some states of USA this is strictly prohibited

2 - great advance changes can overheat and destroy the engine.

3 - maybe you can have some advantage but i would recommend you great attention when you run the engine after this mod.

ciao, Luigi.

GO LUIGI !!! :cheerleader:

Very cool, glad your back at it! I plan on getting back to mine soon also! :fing02:

BR

Beautiful work and thinking things out. If this was easy everyone would be doing it, go go go. I am going through this process now myself and appreciate the time and attention you are applying.

:fing02: Thaaaank you!!! :bliss:

Hi to all.

The project are in progress again. In last months have made much work (family, job and others duties permitting) so now, after a short functional test i have disassembled all to make a deep cleaning everywhere and now i'm reassembly the bike.

Here's some pics:

Agg VFR 20 Luglio 2010 01.jpg

The state of reassembly today

Agg VFR 20 Luglio 2010 03.jpg

The rear subframe that have required much time to be created since that any single accessory location (relays, ECU, battery...) have required a provisional fixing, and a jump to the welder (i have not the TIG).

Sincerely after all this work...dont like me so much. The square tube are easy to put together but i have in mind a "round tube" version that i think will have a better look.

I' m instead satisfied by the accessory location. I have installed all the equipments mounted on the stock subframe and i have added:

• a little tank collected to the cranckcase breather tube that on the stock VFR goes to the air-box.
  
• a simple case for the Power Commander unit
  
• the support for the shock reservoir
  

Agg VFR 20 Luglio 2010 04.jpg

Another view of the subframe

Agg VFR 20 Luglio 2010 15.jpg

Harness will be modified to remove correctly, without a terminal rough cut, any unused wire (lights, turn signal...) and next "good look" positioned.

Agg VFR 20 Luglio 2010 14.jpg

The ECU support are crafted from a an alluminium sheet. Between the device and the support are inserted a rubber strip for vibrations reduction. The simple fixing are obtained from an o-Ring and little hook.

Agg VFR 20 Luglio 2010 12.jpg

Agg VFR 20 Luglio 2010 11.jpg

Two pics that shows the rectifier and the crank breather tank, located in the rear of the subframe. The rectifier position are thought to work in open air to avoid overheating. The same two RR fixing bolts are used on opposite side to fix the support for the fuel pump relay and the barometric sensor.

Agg VFR 20 Luglio 2010 32.jpg

The PAIR valve cover with the tube joint removed (not so nice like the Toro1 covers for his Supecharged VFR but works anyway, maybe in future...)

Agg VFR 20 Luglio 2010 21.jpg

The starter relay and relative fuse box located under the battery support.

Agg VFR 20 Luglio 2010 16.jpg

I have removed the CBS brake system, so the rear caliper have a bridge for the hydraulic connection to the rear master cylinder

Agg VFR 20 Luglio 2010 06.jpg

Sprocket cover are partially cut to have a little "race look" mantaining the protection. I have again the speed sensor mounting holes for the moment. Gear lever works upside, with the first gear above and the others below. Gear linkage fixing bolt are provisional

Agg VFR 20 Luglio 2010 28.jpg

What do you think about, i must mount this mirror-polished alternator cover?

Luigi,

How are you doing and how is the healing going? Your avatar explains a lot of it, just wanted an update on your condition.Hope your doing great!

BR

Hi, BR

I am at 97/98% of rehab. Now i have the right hand knee that have some problem that don't permit me to push hard with excercises. Work on "Track use VFR" are in progress anyway. :fing02:

Thank you.

Ciao, Luigi.

Looking at the X-ray, maybe he had some leftover parts from the YZF1000 or the GSXR that they put in there!

Yeah! I'm thinkin' to apply on the leather suit, near the femur, the advice; "Rider equipped with aftermarket linkage" :laugh: :laugh: :laugh:

Ciao, Luigi

Get well soon!

Thank you!

Ciao, Luigi :fing02:

Luigi, I hope you're feeling better! This bike brings a tear to my eye, how you say, bellisimo? :fing02:

You should post up the measurements of that subframe when you're finished (and able) It looks ideal!

Thank you. You're too kind!!! Ok As soon as possible i'll post some quote and drawing of the alluminium version.

Ciao, Luigi.

hey dude very cool I am looking for rearsets for my bike I have a 99 vfr and was wondering what cbr600 you used the peg set from was it an F2 or F3 or F4 ? or prior ? Thanks for the help good luck on the finished piece.

Hi

Excuse me for the great delay to answer you but i read just today your question.

I've used the 1987 CBR600F footpegs. It seems to me that in USA that model was called "Hurricane".

Anyway is the 1st gen of CBR600 family.

Excuse me again for delay, hope it can useful anyway...

ciao, Luigi.

Hello to all

I'm surprising to not find the british Silkolene in list.

Is not imported in the USA?

I use the Pro 4 Plus 10W-50, have the Jaso MA, the specification of the Japanese Motorcycle Engine Constructors.

ciao, Luigi.

Sorry about the crash Luigi, hopefully not too bad for you.

As for the project, looks interesting.

I have to wonder why not use a front end from 1 bike instead of mixing parts from 4 bikes?

But, if you can make it work right, more power to ya. :fing02:

Simply because i've had this parts free to use...

Anyway if this parts will show limits of performance i will change with something of better in future.

ciao, Luigi.

Hi

Thank you all for your words. Really thank you.

ciao, Luigi.

I don't think you are going to have much success with the components you are using on the front end. If you are going to trust your life to some old junk parts, just don't push it to hard when you get on track because it doesn't look like they will work very well. The rest of what you are doing looks good though, good luck.

Hi,

Yes, i know that the front end equipment is not the ultimate in hi-preformance parts but this is what i've had.

Anyway dont forget that the forks are coming from a Suzuki 1100 GSXR and the brake caliper from a Yamaha 1000 Ex-Up, two bike very fast and, most important, very heavy, more than the VFR at tha actual condition (i think 10/15 kilograms lighter than stock)

More, the fork are fully tuneable in preload, compression and rebound and this is very important for me that i built this bike not only to push hard on track but also to learn the different bike behaviour in reference to the suspension settings.

Anyway thank you for your comment

ciao, Luigi

P.S. I'm sorry but the work of the VFR will be delayed. This is my first post after more than 20 days of hospital.

A car don't respected the STOP signal and so me and my "road use" VFR we have crashed and now i'm walking around with crutches.

ciao a tutti, Luigi.

Hi to all

Here i post the last photos about my work


11th March 2009
This is the situation at the moment.
Instead the alluminium tank of the first photo i've installed a tank of an old 1987 CBR 600 (in US called Hurricane).

Swingarm
The rear train are waiting for a 520 transmission, a chain cover to protect the brake line and a mudguard for the wheel...



Step and support - left hand


Step and support - right hand
This is a modification, very simple to do, to be free to mount any kind of footstep needed. It works in the same way and on the same stock working point without any permanent modification. Now i've mounted the step of the same CBR 600 of the tank, but i can fit any other i need. With the lever mounted in the way you wil see the first gear will be engaged pulling up and the other gears pushing down the lever.

That's all for the moment, hope you will found interesting.

ciao, Luigi.

Hi to all.

An information.

I'm planning to install the Power Commander PCIII USB ECU. Someone can tell me where i can find it a new one at the cheapest price in USA ?

thanks, Luigi.

P.S.

If someone think that this can be expensive for someone living on the other side of the Ocean, i tell you that i bought a pair of OEM front rotor for the road use VFR and i payed, with price list, custom taxes and expedition almost 70 euros (around 95 dollars) less than the best Honda Italian dealer.

Ciao.

Kudos to you - I am having a hard time visualizing the body work. Isnt the exhaust about where the seat would be?

MD

The exhaust is effecitvely a lit bit too high, but i was constrained by the pre-formed dimensions of the bends.

Anyway the seat would be immediately behind the fuel tank and i assure you that i'would be happy to move it forward some more, but here i have the constraints of the tank dimensions.

Thank you all for your considerations and opinions

Ciao, Luigi.

Hi.

First, i will thank you all for your appreciations. I know that this bike is not the ultimate in track performance but the i was fascinated by this unusual project.

Looks awesome so far! Can't wait to see the finished product. Can you post more pics in your gallery? What weight target are you shooting for? What is the foil looking material below the fuel tank? Is that heat shielding material?

-Roger

• In gallery i've posted the sigle parts of the exhaust can, have you saw it?
  
• Actually i've not a target weight. For the moment i think to make the modification to run the bike.
  
• The foil under the tank is just a cotton cover to keep the engine protect from dirt.
  

Interesting.

Why not go with an RC51 or F4i complete front end instead? Should have better suspenders, brakes, and wheel options either way.

Why bother with an aluminum fuel cell on such a heavy bike? Wait, let me guess, you are a welder. :fing02: Nice beads.

• Browsing the site i saw many front end modification with RC51 forks that i assume it 's perfect for VFR, but here in Italy such fork are hard to find and very expensive.
  
• I bought the Suzuki fork mounted many years ago for few euros and so, when i've bought the bike... I was lucky with the measures too. The offset value of the fork is the same and so the trail of the bike remain unchanged.
  
• No, i'm not a welder. The stock tank was OK. The alloy fuel tank is just to try to make something different.
  

Sweet project! Something I've wanted to do myself, but lack the fabricating skills for it. Since you look to have raised the foot pegs those should be fine, but these bikes have a habit of dragging the headers. Maybe your properly sorted suspension will cure that?

Good luck and bring on the pics as you go! :fing02:

• I've designed the foot pegs adapters to have the position of the feet around at same the stock position.
  
• For the bike behavior once finished keep i can say nothing of sure. I just can say that i try to have a driving position charging the front end a little bit more than the stock but i don't want exaggerate. For the rest once on track i think to spend much time finding the right set-up
  

CIAO, Luigi.

Hi to all

This is the first photo of my work on a 1998 5th gen VFR to use on track.

11th March 2009

I've bought crashed with fork bent and here there's the description of the substitutions:

• Forks from a 1989 Suzuki GSXR (with preload, compression and rebound settings).
  
• Front wheel from a Bimota YB9, with adapters for the stock VFR brake rotors
  
• Front brake caliper from a Yamaha FZR 1000, with adapters for the Suzuki forks.
  
• Handlebars from Kawasaki ZX-10R, with adapters for the Suzuki forks.
  
• Footpegs from an old CBR 600, with adapters working on stock fixing points.
  
• Steel exhaust can designed by me.
  
• Rear steel subframe built on my measure.
  
• Rear Ohlins shock with custom setup for my weight (95 kg) lenghtned 5 mm than stock shock
  
• Alloy fuel tank (to finish) with fuel pump from F4 CBR 600.
  

The center stand will be obviously removed.

More to come all the fiberglass components (fairing, tank cover, tail, front and rear fenders, ecc.)

Your opinion?

ciao a tutti, Luigi.

Interesting. Nice work and documentation.

Luigi.

Hi Luigi,

Thanks for posting, but I'm trying to understand why you would want to put anything from a 87 CBR on a 98 or newer VFR800 ?

I guess the VFR800 started as a 97 in the rest of the world, 98 was the first year in the USA. :unsure:

Hi Bailey

Since that the steering stem of the CBR87 ( and probably next models) is perfecly the same of the VFR800 i thought that this in information could be useful in a situation where a substitution of the fork seems impossible because the stem are different.

I suggested the stem of the 1987 CBR because maybe can be simple and cheap find a fork of an old motorcycle.

In fact i've titled the topic "old fork to throw away" just why from an old and unused fork it's possible reuse a part paying less or nothing.

ciao, Luigi.

Hello.

I discovered that the steering fork stem of the 1987 CBR Honda 600 is perfectly the same of the 1989 VFR800.

It's enough to remove the welding under the bottom of the lower triple clamp to have a new item to fit on VFR.

I separated the stem from the yokes removing the bottom welding with a lathe.

After i pressed the stem out with a small hydraulic press.

This can be useful to install another kind of forks that requests the triple clamps substitution too.

More, even the two bikes' steering bearings is the same.

If someone can be interested...

ciao, Luigi.

1998 VFR 800 Stock - Bottom Welding 01mod.jpg

1987 CBR 600 Stock - Welding Removed 01 mod.jpg

VFR 800 - CBR 600 01mod.jpg