My R4

[Maelstrom]

After seeing Joshua102's thread viewtopic.php?f=69&t=49010 (looking brilliant) it inspired me to stick something up. I started a thread in the Yamaha section a long time ago but that was on my 1WG wreck. Later I got hold of a complete 3TJ1. This project will take a long time for many reasons, one of them being my location which means I sort of have to do a lot myself and that means getting the equipment to do it etc.

So the goal is to model it on the R7, well mostly, and in case you don't know what they look like.
Here is the 3TJ1, what I am starting with.


and here is the R7



I have a webpage for the build which includes a lot of detail. http://litetek.co/R4/R4_Project.html

[Maelstrom]

The plan is for a half fairing because I want to see the engine. I was going to buy an R7 unit and hack that up but I ended up buying an early R6 race version so I can fit round headlights. Seat is based on the R7. Radiator is going under the seat. The plan is to drop the weight significantly, 20 to 30 kg would be nice.

Electrics:
The instrument cluster, sourced from an R6, is the same as the R7 except for the white face and there is a page on all the nitty gritty detail for that here http://litetek.co/R4/Guide_R4_InstrumentCluster.html


I am using Tefzel coated wire for the harness and lots of new components.

• Ignition switch is an RFID by MotoGadget (the blue thing is the key)
  Electric water pump to replace the binned mechanical one
  Shindengen SH775 reg-rec
  Cooper-Bussmann fuse boxes (took me months to find them), completely waterproof and can hold micro-relays as well as fuses (nice)
  Headlights are 90mm Hella

Still have to buy the electronic control unit for the pump/fan and the GPS speedo sender.

[Maelstrom]

Wings:
As part of this project I have to get rid of the wings on my 400. Now I am sure that some people think they look good. I am very happy for you, but for me, the word hideous springs to mind. In any case they are not in keeping with the final goal.

Mmmmm beautiful

Cut, cut and keep cutting. I also need to have something level and the laser level comes in handy for that.


Nearly halfway there. I sat the tank on just to see where it sits.


I use a cross-hair laser mounted to the ceiling to square everything.

[Maelstrom]

Water Pump:
Designed a bracket for the EWP and had it 3D printed in the UK, fits perfectly.


Then cut the water pump drive drive off the end of the oil pump shaft.

[Maelstrom]

Fairing Stuff:
First a photoshopped view of the R6 fairing with the lights in. I like it.


Bought an R6 "race" fairing from China. The screen is good, pity you cannot fit it.


This fairing is so bad that it is just going to be a plug for a mould now. First to get the screen to fit by performing a screenectomy. 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.

[Maelstrom]

Shock:
I agonised over this for a while. If I import a Nitron, the tariff and tax will almost double the price. Lucky for me Ohlins opened a factory in Thailand. I found a shock that was almost a perfect match and they revalved it, fitted the correct spring etc.
Old & New


If you want to fit shock A to bike B then you should start with something like this.

[maccas]

Looks great Blair.

Are those dimensions for the 3tj? If so they could save me a lot of measuring when i come to running my 3tj through a suspension package!

Cheers,

Dan

[Maelstrom]

Forks:
I am fitting a bottom triple clamp from the R1 (5VY) that gives me the same offset, and therefore trail, as original. The forks come from the 5PW which has the same travel and disc size as the 400. I found the fork legs in Thailand and the triple clamp and brake calipers I got from eBay in USA. Of course they would not post to Thailand, so I had them sent to a friend and one day he will send them on. The top clamp I will design myself and have milled from Al or Mg, or at the incredibly slow speed that I am moving forward, I might yet get my own mill.


In trying to get these forks sorted I found very little good information, so I made a table and stuck it up. All donations gratefully accepted. With pics please.
http://litetek.co/Guide_USD_ForkDatabase.html

[Maelstrom]

Limbo:
Noun: A term used by motorcyclists when they lack time and/or money to work on their project.
I made a titanium rear disc with a hacksaw and file. Yes, it took a while. Yes, I know it is only cosmetic. Rear brake, who cares?

[Maelstrom]

Carburettors:
They were hideous. I tried all sorts of things to get them reasonable. In the end I shipped them to Matt Harper in the UK and he did his Ultrasonic thing and finished with baked ceramic paint. Very nice. I present before and after. Also a close up. Wrapped in plastic and stored in the hope chest now.