My Custom Monster Build Teaser Pics!

[gatorgrizz27]

Hey guys, I have been working on this project since May, it is really coming together and my "parts needed" list is coming down to single digits!  There is still a lot of welding/fab work to do but I will post a full build thread when it gets done.  Don't mind the ratchet straps/duct tape/wood blocks they are for mock up only so no jokes! I will be happy to answer any questions until then.  I apoligize for no good side shots, my shop is pretty narrow, bikes only!

BTW, this is a 2000 M900 S.i.e. that I picked up off of here after it was wrecked.  I wanted 10 spoke Marchesini wheels, which led to the spiral of mods seen here:

10 Spoke cast Marchesinis with Pilot Powers (thanks TAftonomos )
999 Forks, radial masters, clip ons, and rotors (not here yet)
996 Steering damper under the bottom triple tree
S4 triple trees (upper still needs to be machined for 999 forks)
Frame sleeved internally and braced to strengthen it
Pod filters (should be here tomorrow)
Sargeant seat
Custom rearsets
996 Single sided swingarm
748 Showa shock and linkage
Arrow carbon exhaust cans from an S4RS

It will be painted Gunmetal/Red frame like the S4Rt's

I still need to figure out what headlight I am going to run, feel free to offer any opinions.  The options so far are: Stock, 696, dual round, ?

Next is finishing up the rear of the frame and exhaust hangers, then to build some headers.

If you read my thread about fitting an S2R dash to it, for the time being I will just be replacing my gauge faces with custom white ones.  I have a speedo sensor and can get it to mount, and I am fairly sure I can get the S2R dash to work but the problem is with the wiring.  The S2R dash has no wires between the actual gauges and the plugs, only pins coming out of the circuit board.  What this means is I cannot splice it in without having one of those plugs, and I am not willing to buy a whole wiring harness just to chop the plug off.  If you happen to have a damaged harness with the right dash plug, send me a PM.  Thanks.

[gatorgrizz27]

Few more...



Just did this yesterday, I was going to run a shorty Moto GP can, but it was in the way of my foot so undertail it is, had to make some room for it

[Magnus]

that should wind up being a very unique bike...   keep it coming with the updates if you can, would love to watch the progress.   

[psycledelic]

Where did that swingarm come from?  CF cover?

[gatorgrizz27]

The swingarm is off of an 01 996 that I got from ebay, it came with the carbon guard so I dont know who makes it.

[Juan]

congratulations, it is looking good already..!

[Raux]

recently saw a modded BMW F800ST turned into a streetfighter. The light they used was a Yamaha FZ with LSL brackets. i was thinking about using the same setup.

[flanman]

 

[pitbull]

very cool,
I'm also rebuilding a 2000 900, but without your fabricating, mechanical ability and budget, mine is going to be a fairly stock affair.
I will be watching your build for inspiration.
I don't have any of the spare stuff you mentioned, but many odds and ends type things (ie. foot pegs, wheel axles, ect.). If you end up needing any little stuff, shoot me a pm and I'll see what I have.

[gatorgrizz27]

Nothing noticeable in pictures to update but I have made some more progress:

Steering stabilizer mounted
Pod filters mounted
Oil cooler relocated
Front frame bracing added
Seat mounts added
Battery box/wiring tray added, in progress
Front rotors/brakelines on the way

I am going for a really clean look on this bike, so all of the wiring on the bike is going to be tucked up under the tank where the airbox used to be.  There is a piece of sheetmetal that runs on top of the upper framerail to hold everything, so all that will be visible are the wires dropping down to the throttle bodies and engine sensors, and the wires coming from the handlebars into the frame.  With all of the wiring in such a small place there is now several feet of unneeded wire in the harness, and it is taking a lot of self-control not to cut all of the plugs off and build a new compact harness!  I am tempted to do it but don't want the headache if one of my solder joints isn't connected right.

Thanks for the headlight info, however I am trying to stay away from Japanese styled parts.  I do like LSL's Urban headlight, but at $400 it is way outside my price range.  As for the comment about my budget, you may be surprised at how little it is!  I am still in college and paying for this mostly from the sale of my old bike, so I have to be frugal and find good deals on parts.  For example, I paid $48 for my Arrow exhaust cans because they were off of a wrecked bike.  Since they were getting cut down anyways, it didn't really matter that the collector end was rashed up. 

[brad black]

what did you have to do to get the swingarm to fit the cases?

[gatorgrizz27]

what did you have to do to get the swingarm to fit the cases?

The swingarm pivot on the cases has to be cut down, typically people refer to having it machined, but I used a 4" cutting wheel on a grinder.  I have gotten pretty good with a cutting wheel so you may opt to use something else.  On the left side of the motor (from behind) I cut about 3/4" off of the case.  There are 2 separate needle bearings on the left side, when you cut in you will hit the outer one.  I then ground down the case with a flap disc until it was flush with the inner bearing, which I left alone.  On the right side, I removed the seal and cut and sanded the case down until it was flush with the outer edge of the bearing.  Then the bushings/spacers that fit inside the swingarm have to be sanded down very slightly, probably around 1mm.  My front sprocket is about 2mm inboard of the rear sprocket, so I will sand the mounting face of the sprocket down a bit to get proper chain alignment.  I felt this was much easier than replacing the bearings in the engine case to allow me to move the swingarm over 2mm to the right.  I will take some picture of it when I disassemble the bike for paint to show exactly what I did.

[NAKID]

Let me know if you figure out how to get the front wheel to work with the goldline brakes.

[gatorgrizz27]

Let me know if you figure out how to get the front wheel to work with the goldline brakes.

999 forks with 999 rotors  .  I looked at several different options for this, from machining the monster rotors to machining the fork bottoms for the greater offset.  I found that the extra 5mm offset is actually built into the fork bottoms on the 999, my rotors are on the way but then everything "should" bolt together.  However, the forks require machining the triples (same as SBK fork swap) but since I am running clip ons I decided to use S4 triples and have those machined.  This is also going to require different steering head bearings and moving the keyswitch back a little in the frame to make the steering lock work properly, due to my older style (2000) frame.  I am not yet sure if this will require a 999 front axle as well.

[NAKID]

Damn. Didn't want to go that route...