Project The Yamaha R4 (Glacially Slow Project)

Big Delivery Day
The forks arrived and so did the front Brembos. They appear to have come off a new bike and are complete with a braided line but look as if they have never been used. I think this guy bought a brand new 999 and broke it for parts.
So here is the Brembo collection.

I also have the triple clamps from an 848 but they are sitting at a friend's house in the US.
Finished the design for the rear caliper bracket (Grade 5 Titanium). Less than half the weight of the original part and would be lighter than an aftermarket aluminum one, not that such a thing exists. Hopefully I can get it finished in the next few weeks. I will start producing those for other bikes as well.
cheers
Blair

 

Well I am sort of happy that the standard front forks had to go. It will make the finished bike look more like the little brother of the R7. I was going to buy an R6 front end but it seems to be one of the most expensive available. These parts popped up at bargain prices so I just had to grab them. My headlights are still sitting in the UK so the whole front section of the frame and bodywork is waiting on them and a host of other things. I think I can finish the rear wheel/brake and swingarm while I wait for all this other stuff.

 

Let There Be Light
Finally got my headlights. Another drip falls off the glacier, plop.
More details, http://litetek.co/R4/Guide_R4_Headlights.html, a work in progress of course.

 

Screenectomy
I finally found a piece of aluminium that I can use to modify the R6 fairing mount to fit the 400, but first I need to get the fairing into a finished shape. Well you may recall my not so perfect Chinese fairing. the screen was good and the rest was rubbish. I thought about throwing the whole thing in the bin and going back to square one, but then the Frankenstein method of fixing these problems seemed like a possibility. Since it was impossible to fit the screen to the fairing, I bought a genuine damaged R6 top fairing piece from a wreckers, cut out the screen support on both, and grafted the genuine ABS piece into the fibreglass item. Most of the epoxy is inside of course and I hope it stays bonded long enough to allow me to finish the mould that needs to be made. The finished fit of the ABS piece came out a lot better than I expected and it even appears to be quite true. Some sanding and a little bit of filler and it will be perfect.

Next step on this will be finishing the front support and fitting the headlights.

 

Well some developments.
First of all I have come to the conclusion that if I try to blast the disgusting engine assembled I will probably die of silicosis. But some nice local English gent assures me that he will be able to vapour blast the cases etc for me in about 6 weeks (waiting on arrival of compressor), so it means that I need to pull the engine apart. Took the top end off and set about measuring. all very good. Piston 3 is larger than standard, go figure. Piston 4 is small but so is the cylinder bore, interesting. Reminds me of rummaging around in the spare parts section with a micrometer when I did an engine for the 6-hour. Overall, the wear is minimal, about 0.025 or 0.001" for those who like to work in cubits.





Genuine rings are coming from Hirochi Shop in Japan. I tried to convince them not to charge me domestic consumption tax of 8% but it was like talking to a tree. Also have the Chinese versions coming, don't ask.
In other news, stupid me was too eager with the forks so I am selling them and trying to buy something that is more suitable. If you know anyone who wants some Ducati 999 Showa forks http://litetek.co/Oddments.html a bargain.

 

Does that mean free triple clamps?
Well the first issue is the offset. The original Yamaha (FZR400RR 3TJ1) is 30mm and the Ducati ones I have are 36, which will decrease the trail by 6.5mm to 85.5mm and would speed the steering up to the point of being dangerous. The second issue is that the Ducati forks suit 320mm discs and since I want to reduce weight as much as possible I don't want to buy the larger discs.
Of course there are options. I could just use one BrakeTech iron 320 disc and that would be a lighter option, but then I still have the triple clamp issue. Unfortunately my fork choices are limited so I am mulling it over. The R6 Yamaha stuff seems to be way over priced to me.

 

Well I appreciate the offer Masht. If I do have to go the custom triples I can supply the drawings in any format.
Wow $8000 for some forks. I feel a bit dizzy now, have to sit down.

 

Meanwhile out in the dead zone . . .
Rings arrived from China and the versions ordered from Japan will arrive tomorrow, so I will be able to compare them.
This is the box from China. How about those apples? The FZ400 uses the same rings as the FZR400 3TJ.

 

Ok let's make a new thread called Chinese Rings and owners can report about their purchase.


Chinese Ring Thread
http://2fiftycc.com/index.php?threads/chinese-rings.7840/

 

Shock and Awe
So the front end is sort of stuck for a while until I can find out what forks are long enough. Now about the rear shock, can't put that hideous piece of standard junk back on the R4. A Nitron costs a bundle and then if I try to bring it into this country the costs go right off the scale. Then I remember Tyga talking about how they have Ohlins shocks for some two strokes. Begs the question, where did they get them from? Well what do you know, Ohlins opened a factory here. Poke around on the website and there is a rear shock that is as close to a perfect fit as you could want. Of course it is for a Kawasaki Z800 which weighs the planet, so there will need to be a new spring and re-valving to get it to work on my flyweight Yamaha. Dealer in Bangkok says no. Contact the Ohlins factory and yes sir, three bags full sir, nice Mr Swedish man is going to bend over backwards to set this shock up perfectly for my project. It still wasn't cheap as chips, but you know, in for a penny in for a pound.