My winter project - Page 2

#21 (**permalink**) 02-28-2005, 08:51 PM

Jager, when youre all done with this, are you going to write something up explaining all that you had to do the dry conversion?

So far I got dry clutch housing, 748 Primary and Drive gear (did u figure out if it was a different ratio?), ~2mm machining the back of the a dry clutch basket and that's it?

hailmary · #22 (**permalink**) 12-27-2006, 04:15 AM

hi,any progress?very interesting!

orca122 · #23 (**permalink**) 01-02-2007, 04:43 AM

Howdy just caught this thread and am very intersted. Great project

. I have a SBK frame and was planning an attempt at an 800 insert, mainly because the 800 is legal in lightweight Superbike in CCS. This setup is illegal now due to recent rules that stipulate the engine must be available for purchase in the frame

. I am currently running a 748 in thunderbike. I rode a friends panta and loved the air cooled feel, light and nimble, excellent handling it made the track feel 8 feet wider. I figured this type of build would take me 3 years. I have slowly been accumulating parts as well. I no longer wish to race it but feel it will be excellent anyway. I cannot wait to see the outcome of your "winter" project. Best wishes. sincerely Brad

onespeedpaul · #24 (**permalink**) 01-23-2007, 03:32 PM

bump for progress?

jager · #25 (**permalink**) 01-23-2007, 06:23 PM

Sweet, glad you guys found this thread so I didn't have to go digging around for it. After getting sidetracked with a new job and other things I have started to get the last pieces of this puzzle finished. The bike is currently with Norm. He is mating the sbk exhaust to the ss head and looking at doing a few other things for me. Once this is finished I just need to wire up the bike and then disassemble, clean, and start final assemlby. I hope to be finished by summer. Once I start final assembly I'll be taking lots of pics and posting a final report.

onespeedpaul · #26 (**permalink**) 01-23-2007, 07:28 PM

nice.

did you use SBK swingarm and modify the motor case to fit? also what kind of fuel delivery did you go with, and did you have to do any frame modification there?

jager · #27 (**permalink**) 01-23-2007, 09:10 PM

Quote:

Originally Posted by onespeedpaul

nice.

did you use SBK swingarm and modify the motor case to fit? also what kind of fuel delivery did you go with, and did you have to do any frame modification there?

Yeah I used a complete sbk chassis, so I had to modify the case to fit. I'm using the stock Fuel Injection from the 620 engine. The frame did have to be modified. One of the cross members (one behind the airbox) had to be removed. The engine wouldn't mount up to the frame without it cut. The manifold hits the crossmember.

hailmary · #28 (**permalink**) 01-23-2007, 10:33 PM

hi,im doing the same thing as you,but with a 800 into a 916 frame,a resonably easy swap so far,well at least it could be worse.how did you get the sbk singarm to line up with the frame and engine?mine is about 1/2"out so ive used a much modified monster alloy arm.hurry up we want to see some pictures..............please!

onespeedpaul · #29 (**permalink**) 01-25-2007, 08:31 PM

Quote:

Originally Posted by jager

Yeah I used a complete sbk chassis, so I had to modify the case to fit. I'm using the stock Fuel Injection from the 620 engine. The frame did have to be modified. One of the cross members (one behind the airbox) had to be removed. The engine wouldn't mount up to the frame without it cut. The manifold hits the crossmember.

cool. that's exactly what i was hoping to hear.

ever hear of anyone just using 916/748 cases and bolting up 900/750 (respectively) heads/cylinders/pistons and the left side cover to convert the SBK bottom end to air-cooled? i guess that would be about as difficult as the wet-to-dry clutch conversion. although a dry-clutched 620 is veery appealing...

jager · #30 (**permalink**) 01-31-2007, 01:26 AM

Quote:

Originally Posted by onespeedpaul

cool. that's exactly what i was hoping to hear.

ever hear of anyone just using 916/748 cases and bolting up 900/750 (respectively) heads/cylinders/pistons and the left side cover to convert the SBK bottom end to air-cooled? i guess that would be about as difficult as the wet-to-dry clutch conversion. although a dry-clutched 620 is veery appealing...

Paul,
I remember when we were having this discussion a few years ago there was another guy who was going to try that route, using 9x6/748 cases and 900 internals. I'm pretty sure he found out it wouldn't work, although I think he might have be trying a different approach than you. You can check Brad's Ducati Capacities page in this Moto One Performance notebook for a bunch of info on that kind of stuff.

The dry clutch conversion on the 620 was not bad at all. The worse part was popping the primary gear off. That thing is a bitch to remove. Ducati tool cost around $250 or so. I got a $99 dollar hydraulic gear puller that after some fooling around with I got the gear out without too much of a fight.

onespeedpaul · #31 (**permalink**) 01-31-2007, 02:46 AM

that's cool the clutch wasn't too bad.

and wow, thanks for that link. looks like i may run into some issues building the hybrid motor i thought i could. i've now got a '97 748, that i'm looking to swap out the pistons/cyl's/heads/maybe studs and left side cover from a '99 M750. same bore and stroke, but if the small ends of the rods and the stud spacing are different, then i guess i'm hosed.

haha, i guess i'll let you know next week what's compatible and not.

well if it dosen't work out, i'll still have a perfectly good running 748....and i'll just keep searching for a good 900SS motor to play with.

onespeedpaul · #32 (**permalink**) 02-05-2007, 09:43 PM

how's the progress jager?

i have none to report, the stud spacing from 748-750 is different.
i did find out that, a 900 cyl/head will fit on a 748 tho to make it an 818cc motor....i however have given up, and am now just looking for a complete 900 2V motor...

hailmary · #33 (**permalink**) 02-06-2007, 07:38 AM

hi,after much cutting and welding,heres what i came up with so far

916 frame
800ss motor (i think its an 800?6 speed box,wet clutch,im told 750s dont have an 6 speed?)
rear suspesion is ss style cantilever

monster swingarm (brace yet to be made and welded on)
38mm equal length exhaust
999 tank
lots of work

hows yours looking?

onespeedpaul · #34 (**permalink**) 02-06-2007, 01:22 PM

wow.

can i ask why you decided to use a monster swingarm vs. 916 swingarm?

how about the 999 tank/seat? difficult?

great to see some progress!

jager · #35 (**permalink**) 02-06-2007, 04:43 PM

Quote:

Originally Posted by onespeedpaul

how's the progress jager?

i have none to report, the stud spacing from 748-750 is different.
i did find out that, a 900 cyl/head will fit on a 748 tho to make it an 818cc motor....i however have given up, and am now just looking for a complete 900 2V motor...

The bike is still with Norm, he is finishing up the exhaust and a few other things. I have no garage to work in atm so I told Norm that there was no rush. Hopefully I'll have a place to work by the end of the month.

Here is a pic I took a while ago. I can't find the pics I had of the other side with the dry clutch. I will check my home computer later today.

Clicky for bigger pics...

HailMary,
Nice work. I can't weld, so there was no frame alterations for me. I just cit the crossmember under the airbox so the engine would fit. Is that a gsxr tail?

hailmary · #36 (**permalink**) 02-06-2007, 06:26 PM

hi

yes its a k6 gsxr600 fibreglass tail,not sure if i will stay with it .but it kinda follows the lines of the tank?
i didnt want to cut the motor,hence the monster swingarm,although if i could find a late model 1000ds arm i would use that instead.
the monster arm was all i could find at the time.
999 tank only needed two small location tubes welded onto the inside of the frame behind the headstock,the subframe was a big job,i did it four times b4 i was happy with it,once i get the brace fitted to the arm i should get some more progress,i just need to sodium blast the frame and paint it then i can start putting it all back together

onespeedpaul · #37 (**permalink**) 02-06-2007, 07:10 PM

nice pics!

and.... i thought the GSXR tail flows nicely with the 999 tank.

onespeedpaul · #38 (**permalink**) 02-11-2007, 11:28 PM

hey jager,

can i get a rundown one more time of cutting down the cases, as i'm just about ready to do that.

any details or issues i should be concerned with? from what i gathered you just knocked out the swingarm bearing races and used a cut off wheel following the lines correct?

i'm assuming having the two new edges perfectly square isn't a huge deal, but that they need to be close. i was thinking of using a bicycle head tube or bottom bracket facing tool to square the sides. anyways, if they just need to be close i'm good with that.

as far as shimming i'm assuming it will be a matter of testing and re-testing to get the swingarm, case and frame good and snug. any thoughts there?

thanks for your time, -paul

jager · #39 (**permalink**) 02-13-2007, 05:20 PM

Yeah that is bacially the idea. There are marks on the case where you need to cut it down to. I got it as close as a could to those lines. The alt side was much easier, since there is more engine, that you don't want to cut, on the clutch side so you have to be careful. Once I got it close I used a sanding wheel to remove just enough material, then check again to see if the swingarm would fit.

onespeedpaul · #40 (**permalink**) 02-15-2007, 01:02 AM

thanks, i got the alternator side cut off.

any tips on knocking out the races???

man, those things are in there.....