Track Bike CBR600 Evo-II My personal Project finished 2010

Here and Another new theme – Project № 1 for 2010 year CBR600F2 – a toy for entertainment and how we can revitalize and restore life to our old CBR!
How and what we can improve on his motorcycle with its own forces and minimum resources.I will try to give the best of me,to show in detail possible with more accurate explanations for each action, and conversion of this old motorcycle!

This new for me project starting on monday 15.09.2009

Hi it’s time to start explanation the improvements for Bike

Everything started from here so………………

0.Crash frame sliders one Standard,cheap and recommended MOD

- Just need to work out this detail of a drawing two times,for left and right side!

1.Forks Swap  -  ZXR400H UPSD to CBR600F2

 However, I must start somewhere.To start on the row we do things, what and why it happened and what had to be changed!
Putting UPSD Forks from KAWASAKI ZXR400H took much less time than I ever expected, all girded be limited to replacement of the axis of the triple clamp’s (from Kawasaki) camped in a motorcycle frame with that of the triple clamp’s a Honda CBR600 F2 / F3/F4/F4i ……….. I use from F4i (so I had available) and everything was fast, incredibly easy and perfect.!!!!Difference in diameter – internal aperture of the axis of the triple clamp’s (from Kawasaki) has less than 2 millimeters in outer diameter of the triple clamp’s Honda CBR600 F2/F3/F4/F4i – thus facilitating my work repeatedly with a Lathe , one Coordinates cutter, 10 tons press and welding machine – the work was completed in 1 hour and the result was 101% of the wildest expectations!

 UPSD Forks from KAWASAKI ZXR400H is slightly shorter (difference is 26 millimeters) of the original work forks SHOWA which are equipped with Honda motorcycle models – CBR600F2/F3/F4.Also and so there is a difference in the location of the handles in the original and in Kawasaki, It is because of this fact is necessary and unnecessary to modify the fuel tank of the largest F2, especially in front of triple clamp’s to the forks of the rider and to also quite high – which prevents the posture of the rider on the motorcycle, it is precisely because and require redesign of the fuel tank to smaller dimensions, which also allows removal of the rider in the saddle with 6-7 centimeters ahead of the front axle combined into one with much more robust and stable UPSD motorcycle becomes an incredible stability and will equip itself with greater confidence for uncompromising behavior Race Track!!
For me this is a perfect and incredibly good upgrade for Honda CBR600F2!!

fig.1 fig.2

** Note
The internal diameter of less than 2 millimeters in outer diameter of the central tube of the triple clamp by opening CBR600F2 is an ideal surface, perpendicularity and parallelism is a need for intervention

Use bearings from CBR not from ZXR,because the bearings from ZXR are larger compared to replacing them in the frame of CBR600F2/F3 and for this reason you must use some parts from your old forks like a down triple clamps – you must cut him,you need to use central tube of the triple clamp from CBR600F2/F3/F4!

Cut central tube of the triple clamp on ZXR400 like on fig.1 after remove central tube of the triple clamp from CBR600 like fig.2 and put in to the triple clamp from ZXR like on fig.3 (use a powerful press for putting)

fig.3                                                                               fig.4

After all of this operations welded like on the fig.4 this is very important procedure!!!

…………………It is because of this fact is necessary and unnecessary to modify the largest fuel tank of the CBR600F2/F3, especially in front of triple clamp’s to the forks of the rider and to also quite high – which prevents the posture of the rider on the motorcycle, it is precisely because and require redesign of the fuel tank to smaller dimensions………………

Here it is result after the “resizing” of the fuel tank………………………

2. Rear Wheel swap 4,5″ to 5,5″

Second and very important challenge to Me – it was still trying to replace (replace) the original (existing) rear wheel that is 4.5 inches with a width of such a model CBR900RR/CBR919RR which wheel has the same design as the 600F2 but with 5 , 5 inches wide!
This MOD has been very quick and easy – contrary to all my expectations, this change proved to be – fast, easy, cheap, which is still all original except the rear wheel close ………….. …… it was replaced with 5.5 “wheel, giving access to a wide choice of rear tires for this bike, in good driving and the track and greater certainty in the management of bends which give us the most great pleasure in riding a motorcycle!To be able to replace your “old” (original) 4.5 “inches rear wheel with this 5.5″ inches as you explained, you need to use a drawing of the photo interpretations, do not forget that all dimensions are in mm ( metric)
Acquire (buy, get from a friend, get a second hand) with the rim is 5.5 inches by CBR900RR or CBR919RR fully equipped, remove the flange on the rear sprocket, verify its size and dimensions bench-marked against them in the drawing – process to flange dimensions such as marked on the plan which I have prepared for you!
Then craft and a collar with an internal diameter of 2 millimeters Longitude diameter with the axis of the rear wheel external diameter of 20 millimeters and 34 millimeters of hub(fig.3)!!You can save drawing from ->  sprocket holder drawing

For rear Sprocket you need 5pcs. to set rear sprocket on Sprocket Holder(fig.1) and 1pcs. from wheel spacer(fig.2):

fig.1 fig.2 fig.3

3.Universal Race rearset on CBR600F2/F3

This is one good up-grade for all bikes,If at least try to ride a motorcycle that is equipped with aftermarket Race rearsets – will surely understand what I mean!!!For This up-grade you need one piece of each riser plates drawing.  PDF drawings

fig.1                                                                           fig.2

As in Example one set Universal Race rearset like this(very good quality for low price)

4. RAM-Air for CBR600F2

If you change your FORKS…………. you have a Large of space for Ram-Air MOD

You can make a very interesting MOD to supply air box of your Motorcycle with a cold and oxygen-rich air!
This seemingly side solution that occurred to me in one rainy day, prompted by findings in the difference of the power available to the other my TL1000R Motorcycle factory which is equipped with SRAD system – The more cold and wet was the air with so much more power I had !
Therefore, when due FORKS UPSD replacement of the motorcycle, replacing what I provide – ideally allow the development of Central air tube to deliver cold and oxygen-rich air of the “entrance” of the air box and thereby increase engine power, and improve the throttle response because there is no way to make a drawing of this MOD will seek to publish in the best possible pictures and made further clarifications to them!
I want to clarify that these improvements – replacement of Standard FORKS with UPSD Forks and construction of Ram-air is only possible if no explicit holding that to maintain the original fairings on your motorcycle!!!

4. 599cc to 637cc

 This is next step:  +2mm pistons to over-bored engine from 599cc. to 637cc.Opportunities of using parts from the new generation “F4i” Our much easier and also gives us the choice for the same time, very cheap and very good substitute for expensive WISECO, JE-Pistons and other brands of after market pistons 

Now this Bike is finished!!

MY LOVE BIKE

And here is the last updated bike list :

1. Up side down fork from Kawasaki ZXR400 with “WhitePower” internals
2. White power progressive fork springs
3. 5,5″ Rear wheel from CBR900RR
4. Ohlins 18 steps steering dempfer
5. K&N Race Air filter
6. K&N Race Jet Kit Stage-7
7. Cold Air Box(Isolated)
8. Ram Air direct system
9. NIKKO – Ignition advance
10. NIKKO – Quick shifter
11. Universal race rearset
12. D&D Race exhaust system
13. Custom made race silencer
14. Thermo wraped exhaust header
15. ABS for rear brake caliper
16. 6 pistons Front brake caliper GSX-R1000K2
17. Steel front brake line
18. 1/6 turn throttle “HRC specification”
19. “ORAM Suspension” Italy race rear shock
20. “Light Tech” fuel cap
21. BREMBO Radial Front brake master 19×20
22. KOSO RX-2NR Race cockpit with analog tacho
23. “CRG” clutch lever
24. GSX-R750 Clip Ons
25. CBR1000RR ’08 Hannspree Ten kate Honda – Full Race body kit Fairings
26. DB Windscreen
27. Frame sliders
28. frame sliders/service points for swingarm
29. Tailor and relocated fuel tank
30. 520 chain conversion – “XYT 520Gold X-ring racing chain”
31. JT Alu Sprockets 14/46
32. Adjustable cam sprockets
33. Custom cam timing
34. Special custom Body paint
35. Relocated battery box
36. Custom made sub-frame
37. Brembo handlebar grips
38. CBR900 Kill switch
39. DENSO Iridium IUH27R
40. Maximum reduce weight – full wet weight with all things like a – Full Fuel tank,Oil,Antifreeze,Battery and so on – 159.6kg  

 PIC’s from finished project!

Bike PIC’s & On board Video

CBR600EvoII first time on the Race track

One  SS600 Bike  is very important that such a motorcycle to the right places for which it was created

And the other really nice thing is sometimes something small you raise morale ……………….. but the effect is cool for that Serve huge thank the organizers of this event! 

And when you remember that everything started from here as follows:

and after in the end of  2009 season from here:

and on the finish my beautiful result:

********** I love this toy

Pls remember on the race track is secure but no body is not insure from the falls!!

  – do not try this at home