Taken a while, track bike anyone?

Firstly I would just like to say how much I love these bikes and how invaluable a Haynes manual truly is.
I did not listen to anyone that told me it couldn’t be done and went on my own path (it was very long and windy with many dead ends).
The bike started out as a commuter that had been loved and very well serviced.

Work then started on a mammoth restoration project.
Complete strip down and replacement of most moving parts including powder coating of frame, new shock, fork rebuild with new springs, you get the idea.

After much time and money thrown at the bike it was done and looked not bad.

Start of the rebuild

Bike getting towards the end (as I thought at the time) of the build.

I finished the build and used the bike for a season of track days, going round the country to many different circuits.
I felt the bike was letting me down a bit, so decided on a new project for the winter.
Upgrading the engine to a 660cc stroker with ported head and high lift cam shaft.
I did quite a bit of research on this before undertaking such a build and it seemed quite easy.
Bottom half of a FZR600 with the top half of a YZF600r, making a much better more powerful and stronger engine.
How wrong I was. There are many things that the forums just don’t tell you, but I have learnt it all now (if anyone else fancies this conversion talk to me and I can explain some of the issues).



Head looking lovely, skimmed, ported and cleaned with the valves re-seated.

Engine build nearing complete (or so I thought)
Hi lift cams installed with all clearances checked and adjusted (larger shims due to the cam shaft).

Engine now in with new Dyna coils and cleaned, balanced and re-jetted carbs.
I was thinking nearly there now, but so much still to do.
This was when things started to really take some time.
Wanted to fit the YZF oil cooler (was suggested on one of the forums), but this was not a straight swap and needed some fairly major mods to the block.
The sprocket also doesn’t line up with the back wheel, so again bit of work required here.

Oh
I totally forgot
You have to change the loom and cdi unit as totally different.


I then decided that an electronic dash with gear indicator would be good (just a bit more work)

I also decided on race fairings to complete the look, which again turned out to be a bit more work than expected as had to fabricate something to actually sit on


The bike is finished (wrong again)

During the build I had installed an EBC race clutch set with supposedly “upgraded springs”
I thought I would get the bike dyno tested before I went back on the track.
The bike sounded fantastic and flew up the revs. The problem was it went up the revs a bit too quick. The clutch was slipping which was very frustrating. After all this work the bike was no good, but another way of looking at it was I now had an engine that was producing more power than the clutch could handle.
The dyno test had got up to 90 at the back wheel (more than the stock YZF600R produced when first out of the factory
The problem was getting a bigger clutch to fit.

Reading on more forums the YZF600R clutch can be used.
I would just like to make it clear, it does fit but again there are some mods required to the block and the push rod.

I installed a complete new clutch with plates, friction plates and springs. The YZF clutch is a bigger unit with more and larger springs.
The bike is now complete and rides really well, down a bit on speed but I think this is to do with incorrect sprocket 

I am looking to go on one more track day with the bike (going to drop the rear sprocket a couple of teeth) but I will then be looking to sell the bike.
I have a massive spares package (engines, wheels etc etc)
If anyone fancies a new old toy give me a shout

Loving your work! Thanks for posting!

Just as an update, that last track day was at Donnington which didn’t go well.
Not sure what happened exactly but I think the chain adjuster plate at the back of the swing arm snapped. This allowed the adjuster to disappear up the swing arm and meant the chain had a lot of slack (far too much). Unfortunately this all happened as I was travelling down the start finish straight!
Needless to say it didn’t end well with the chain coming off and wrapping round the sprocket carrier and locking the back wheel up briefly.
Fortunately it didn’t spit me off but it has caused some damage to the selector forks (I think) as it wants to keep changing gear all the time.
Looks like another rebuild is on the cards
Still I got a 2007 ZX6R as my new track bike. I must admit it is a lot quicker, handles better and has a slipper clutch as standard