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Discussion Starter · #1 · (Edited)
Alas the 2006 racing season is over, time now for the long wrenching season to get ready for 2007.

2006 was a pretty good season for us, we raced a 2005 SV650 in the AFM 650 Twins and Formula 4 classes. By the end of year we had both class championships by 100 and 150 points, respectively. Not bad considering the max points for a win is 75 and we have only 8 rounds. My teammates also had fantastic years taking 2nd in 650T and 3rd in F4, and taking 2nd and 3rd in the 500 Twins class riding custom built SV500's. At the end of the year all our teams hard work paid off with not only multiple class championships, but also 2 riders from our team earning AFM top 10 plates for 2007!

Well, season is done, bikes are sold, and here we are stuck with more time than sense until a fancy new R6 arrived on my doorstep. Plans are to trade up from the 650 classes to the 600 classes for 2007 and by all accounts the R6 is the best platform to start from. Now a little info on the AFM classes, the 600 Superbike class is close in line with AMA superbike rules, meaning bore and stroke must remain stock but engine work is pretty unregulated, as well as aftermarket forks, frame bracing, etc. The AFM Production rules are much more strict, much inline with AMA supersport rules. ie. very little engine work, fork internals only, stock wheels, brakes, frames, electronics, etc. The goal for this R6 is to meet and be competitive under both class rules, even if I can't ride the damn thing to it's potential. ;)

I'm guessing this build will take some time, so please check back if you are interested. Thanks in advance to everyone who is helping us out on this!

Lets get to work! Here is the bike as it arrived, 873 easy street miles on it, from the looks of the chicken strips they were very easy miles. ;) The front tire still had the painted stripe down it's tread. I put about 20 street miles on it to get to-and-from the DMV before stripping it down. FYI, the DMV gets very cranky when you bring a bare frame down to title it, so make sure that gets done up front! (how do I know that?!?).



After the DMV circus we slapped on some Michelin DOT race take offs on the rims and my tuner Zoran from Twinworks Factory took the bike down to a trackday at Willow Springs just to see how it would do all stock. Of course I was a little irritated that I was sitting at work while Z was wringing the R6's neck, but gotta' pay the bills, ya know. I called him at noon to see if he had thrown the bike down the road yet and he said 'No, this thing is facking great man, you might had to buy another one 'cause I might just keep this one'. 'Cool' I though, if it is decent stock we might just have a chance...
 

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Sounds like a lot of fun!
 

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Discussion Starter · #3 ·
So the trackday was good, even if I still haven't been able to ride the R6 further than the DMV (not that I am annoyed.. ;) ). Zoran did fiddle with the stock clickers a bit and got the bike to a pretty good set up fir stock. This is worth it's weight in gold because it should be pretty good outa-the box whenever I get a chance to ride it.

A couple days later I started the teardown. All the street stuff has got to go, mirrors, fairings, lights, horn, exhaust, all that stuff. It has been a while since we have played with a new stock streetbike other than a Suzuki... Things I noticed are:

1. Damn there are a lot of fasteners! The fairings are made of a gazillion parts and each one has at least 3 fasteners, that makes gazillion X 3 fasteners! I did like some of the slip-fits and clips on the fairing though.

2. The tank is a bit annoying, the plastic cover on the front makes a good handle, but there is no tank prop or easy way to keep the tank up, short of a bungee. I do like how the fues is down low, almost under the seat.

3. The stock exhaust looks tiny and trick, but it must be full of rocks. I was surprised by the weight, but no worries I have a new Leo Vince full titanium 'Corsa' system that is waiting to go on later...

4. Love the subframe, small, well designed, very trick.

Most of these parts will end up on Ebay, I have little use for them and I hate having good stuff kicking around the garage.. This is what the bike looks like with most of the street stuff removed.



Pretty densly packed inside that bodywork! Next to come off is the exhaust. This is one part that I will be keeping just in case a Laguna date jumps out at my. I am nervous that the bike will pass at laguna, even with the stock pipe, this thing screams!



Here she is, all nekked for all to see. Without the exhaust the chassis looks half the size! The next step is to make heads or tails of the mess under the tank. This thing is far more complicated than the SV when it comes to vacuum and vent lines. I will be taking my time to make sure I don't remove the wrong lines! Here is when the official service manual is worth it's weight in gold.



Look at that mess! homefully it will be cleaner by the time all is said and done. This happens to be a california model as well, I don't think Yamaha has gone to the 50-state models yet so this mess should be worse than most..

That's all for now, next will be safety wiring the bike and adding race parts as they arrive in the mail...

stay tuned.
 

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Absolutely beautiful... *tears*
 

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Discussion Starter · #7 ·
Nothing was wrong with it, 873 miles perfect condition. I bought a set of spare wheels that I mounted take off's, that's what you see on there now.
 

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Discussion Starter · #9 ·
Spent the night working on the bike, cleaning, poking around, etc. I got the airbox off and started attacking the big mess of wires and hoses under the thank. As you can see it is much cleaner now.



I removed the tank vent and overflow lines, this is a racebike so I don't have to worry too much about overfilling. I also removed the O2 sensor and wiring, sidestand and wiring, and the carcoal canister and associated hoses. Remember to cap off those vacuum lines on the throttle bodies. For the side stand wiring I made a shunt harness so the bike always senses the side stand is 'up', basically disabling the 'starter disable'. I also removed the air induction system, but I am waiting for the block off plates to arrive from Graves. I am also leaving the big rubber 'sheet' on top of the block, the bottom of the sheet has some heat-shielding on it, presumably to keep engine heat away from the tank and TB's.



This pic I took for grins, I looked all over for some information on the Fly-By-Wire system on this bike but found little info. You can see the throttle cables on the left of the TB's, it looks like the cables actuate the sensor to the right of the cables. The actual butterfly motor is the block right over the #3 TB. Nice.
 

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Arnold_R1 said:
Nice, keep us posted! Zoran is the shiz! Are you racing AFM next year or possible WSMC! :sing
Kurt's way faster than us dude, he was passing me while I was on it, looking over his shoulder giving me the thumbs up, as he's turning bout a buck twenty onto the front straight at Fernley... He's the real deal. :bow
 

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Discussion Starter · #11 ·
Yesterday I also received a care package from Morse Racing Products with a set of GP Composites bodywork. I know some other board members here have had good dealings with Scott at Morse and I just have to back that up. Scott is a stand-up guy, very helpful on the phone and the set of bodywork arrived 2 days after talking to him. All that and very reasonably priced as well, doesn’t get much batter than that, thanks Scott!



I got the full set, including the fender and draft-shield. What is nice about this set is that it uses the stock seat. I hate those superbike tails with the rock-hard foam pad but some people swear by them. Under inspection I have to say that I am very impressed with the quality of the glass. There are no pits or voids in the gel-coat as is typical with race glass. Since I do my own paint I know how shitty bodywork can ruin your day.... I am tempted to just start spraying paint but the little annoying voice in the back of my head kept saying 'check the fit, check the fit' so I mocked the bodywork up on the bike.



Not bad! everything fit as advertised, the set came pre-drilled and the fasteners all lined up and screwed right the frame. The ram air duct fits nicely into the nose, but I will have to trim a little bit of glue-buildup for the ram air to seat all the way in. The draft-shield will also need to be drilled to attach it to the tail section, not a problem. The exhaust is off the bike so I don't know if this set will fit over the stock exhaust, but that doesn’t affect us. The good thing about this set of bodywork is that it is both AMA Formula Extreme and Supersport legal.

Took the bodywork off and I feel confident enough now to spray the paint. I will spare all the details of painting, I know that stuff can be boring. I will say again that the finish on the glass is good enough that I will just scuff and spray, no finishing work is required, that's bitchin. I will have to sand and prime the tank and tank cover though before I do the final color. For paint I use a good automotive quality single stage polyurethane, base-clear systems look good but this is a racebike for crying out loud, it's just going to hit the ground!! ;)
 

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Discussion Starter · #12 ·
Arnold_R1 said:
Nice, keep us posted! Zoran is the shiz! Are you racing AFM next year or possible WSMC! :sing
Hey Arnold,

I will be doing AFM next year, but I do go down to WSMC in our off-season for practice and seat time. I won't make this month but maybe next? If you are down there give me a shout.
 

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prolariot said:
Hey Arnold,

I will be doing AFM next year, but I do go down to WSMC in our off-season for practice and seat time. I won't make this month but maybe next? If you are down there give me a shout.
Nice, did you do the 4 hr endurance last month? My friend Mike and Brienne raced in it and said it was a blast!

 

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Discussion Starter · #14 ·
yea, I know both Mike and Brienne,

They were riding in the 600 class on Mike's SV. They did awesome for the first time at sears! Brienna actually beat me in a 550SB race back in 04 down there at WSMC, girl can ride...

Mike should be going to the ZoomZoom trackday at Sears on the 6th of december, I should be instructing there that day too.
 

· Smiley Whore
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hey I sent u a pm regarding the oem plastics... even on ebay too, never heard from you.
 

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Hey Kurt, glad to see you're digging into the new ride right away. I'm itching to get a hold of my 07 so I can start a very similar process for next year. I plan to do a thread just like this but focus on the weight savings, I've always been curious to know just how much weight each phase of a full on race prep really saves. Keep the pics and detail coming, I can use it for a reference once I get my new R6. :)

I should be up at the T-Hill day on the 26th and I'll definitely be there on the 6th at Infineon, can't miss that one!

Bishop
 

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niiiiiiiice
 

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prolariot said:
yea, I know both Mike and Brienne,

They were riding in the 600 class on Mike's SV. They did awesome for the first time at sears! Brienna actually beat me in a 550SB race back in 04 down there at WSMC, girl can ride...

Mike should be going to the ZoomZoom trackday at Sears on the 6th of december, I should be instructing there that day too.
My buddy James has Brienna's old SV. They're awesome bikes!




The GP composites bodywork are excellent stuff. :yes I'm running that same bodywork and it has a lot of flex. I wanna say more than the Sharkskinz stuff and way more than the Catalyst.

Mike used to live down here in SD and we used to riding all the time. That guy is comedy too! :D
 
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