My SRAD 600 Track Build - Suzuki GSX-R Motorcycle Forums Gixxer.com
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post #1 of 61 (permalink) Old 07-19-2016, 08:16 PM Thread Starter
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My SRAD 600 Track Build

So after having a road accident in May 2016 and my bike now being subject to a cat B, I figured now would be the time to change it to a track only version. Here are some pics from before and after the build. The bike is not yet finished yet but it's very close now. But if anyone has any ideas for upgrades or suggestions then feel free to comment.

These are the first photos I saw when the bike had been brought back to me. :-(











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post #2 of 61 (permalink) Old 07-19-2016, 08:23 PM Thread Starter
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Re: My SRAD 600 Track Build

Thankfully I have had the engine running since, so I know all is well in that area. I began to strip the bike completely and started overhauling things that didn't necessarily need fixing but I thought as I am starting from scratch I may as well make her look and feel as new as possible.

I started with the rear caliper and rear master cylinder. Giving them both a thorough clean and re-spray. The rear caliper has been fitted with new seals, nipples, copper washers and a new rubber joining washer. I installed a a rebuild kit in the master cylinder not so long so I didn't overhaul that.







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post #3 of 61 (permalink) Old 07-19-2016, 08:29 PM Thread Starter
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Re: My SRAD 600 Track Build

Next was the sprocket carrier. sanded down and resprayed.






After that was the stator cover as I had cracked the last one from the accident so bought a second hand one. wasn't too bothered about it's condition as I knew I'd be restoring it anyway.







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post #4 of 61 (permalink) Old 07-19-2016, 08:32 PM Thread Starter
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Re: My SRAD 600 Track Build

I managed to glue the left RAM air duct back together as it split in two. however it did so in quite a clean fashion so more like a jig saw piece to put it back together. Once that was complete I then sanded and repainted them.



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post #5 of 61 (permalink) Old 07-19-2016, 08:39 PM Thread Starter
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Re: My SRAD 600 Track Build

As the forks pretty much took all the impact I thought now was the time to upgrade the forks. I went for the 2006 GSXR upside down forks. I was lucky enough to find a deal on eBay which included the top and bottom yokes and also the calipers. won the bid at 160

The seller told me they had been sitting outside for quite a while getting weathered over time so I knew they were going to need overhauling anyway but at that price I couldn't say no!










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post #6 of 61 (permalink) Old 07-19-2016, 08:44 PM Thread Starter
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Re: My SRAD 600 Track Build

Well they say if it sounds too good to be true then it is and partly in this case it was, all was well with the forks however the caliper bolts were unbelievably seized that in the end I had to write them off. Luckily my mate had some GSXR k4 1000 calipers about so I have ended up using them instead. I ended up having some fitment issues with those, but more on that later.




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post #7 of 61 (permalink) Old 07-19-2016, 08:50 PM
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Re: My SRAD 600 Track Build

Are you going to replace the fork internals? What about the rear shock?
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post #8 of 61 (permalink) Old 07-19-2016, 09:23 PM Thread Starter
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Re: My SRAD 600 Track Build

I was tempted to buy a spring compressor to overhaul the forks but with the cheapest one I found being about 50 I ended up watching a few YouTube videos and doing some research online and ended up making my own out of M8 threaded bar, nuts and washers, a block of wood and to M6 allen head screws. It worked a treat!

I completely drained all the old oil out and removed and old gunk from inside. In went the new pressure and dust seals along with nice and shiny fork oil. recommended oil for these forks is 5W as per the manual.

I mounted them to the bike just for visual purposes. As this a K6 front end conversion I will need to adjust the fork legs in the yoke to match the wheel base of the SRAD.










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post #9 of 61 (permalink) Old 07-19-2016, 09:24 PM
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Re: My SRAD 600 Track Build

Quote:
Originally Posted by LM88 View Post
As the forks pretty much took all the impact I thought now was the time to upgrade the forks.
What about the frame? It's damn near impossible to do that kind of front end damage without tweaking the frame. Any plans to get the frame replaced or at least spec'd out by an authorized company to ensure that it's perfectly aligned?

Also I'd go with aftermarket case covers for their added crash protection. That's all I've got for now.
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post #10 of 61 (permalink) Old 07-19-2016, 09:32 PM Thread Starter
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Re: My SRAD 600 Track Build

Now was the time for the engine to come out as I had the frame sent off for powder coating. One thing to note for anyone wanting to go this far with their bike. Take pictures of wire routing. It took me quite a while to figure out the correct routing of all the cables and wires.

I was tempted to delve into the engine to do some light engine work and basically a refresh of the engine as she is an old girl. However after much debate and being told on more than one occasion to leave it as there are no current problems with the engine. I only had the valve clearances checked to which they were all within tolerance.












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post #11 of 61 (permalink) Old 07-19-2016, 09:35 PM Thread Starter
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Re: My SRAD 600 Track Build

I was worried about the condition of the valves on the outlet side. Maybe someone can shed some accurate light on their condition?


INLET



OUTLET


Good job I checked the clutch cable


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post #12 of 61 (permalink) Old 07-19-2016, 09:41 PM Thread Starter
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Re: My SRAD 600 Track Build

The forks that I won on ebay came with the wheel spindle but no spacer. I ended up having a captive spacer made for the wheel which is such a nice treat when taking the wheel on and off as you dont have to fidle with aligning the spacer then putting the wheel back in.

The captive spacer just pops into the wheel bearing dust seal and removes easily with your fingers if you need to. I had these made up by a guy who goes by the name " Joe Can Make It " this is his Facebook page https://www.facebook.com/joecanmakeit/?fref=ts



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post #13 of 61 (permalink) Old 07-19-2016, 09:49 PM Thread Starter
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Re: My SRAD 600 Track Build

Since owning the bike I've never had the Ohlins rear shock serviced. So now seemed like the perfect time to do it. I have had it sent off to an ohlins specialist but is not back with me just yet. They will be fitting an ohlins spring for my weight as well which will help with overall feel and handling of the bike....oh yeah and I get a nice sparkly yellow spring


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post #14 of 61 (permalink) Old 07-20-2016, 06:01 AM Thread Starter
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Re: My SRAD 600 Track Build

Quote:
Originally Posted by Carnage View Post
What about the frame? It's damn near impossible to do that kind of front end damage without tweaking the frame. Any plans to get the frame replaced or at least spec'd out by an authorized company to ensure that it's perfectly aligned?

Also I'd go with aftermarket case covers for their added crash protection. That's all I've got for now.
Surprisingly the frame has been tested and is fine. The crash was only at about 20mph. Still curious how the forks managed to split in two at that speed though!

I have had a look for after market case covers but can't seem to find any for my bike. If you have some links to engine, stator or clutch cover protectors then feel free to let me know
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post #15 of 61 (permalink) Old 07-20-2016, 06:06 AM Thread Starter
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Re: My SRAD 600 Track Build

So now onto my dilemma with he K4 GSXR 100 calipers going onto the k6 forks. The k4's don't have the recessed section in the caliper like the k6's do. so again used https://www.facebook.com/joecanmakeit/?fref=ts to make me some custom spacers.











on my drawing it says that the "length" is 6.7mm i actually changed that to 13.25mm as i am going to be using the 320mm discs instead of the 310mm discs which is the standard size disc for k4 and k6 calipers.



I have tried the spacers on the forks and they work a treat.
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post #16 of 61 (permalink) Old 07-20-2016, 06:21 AM Thread Starter
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Re: My SRAD 600 Track Build

I now have the frame back all nicely powder coated black . Engine is now back in and I have built up the rear end with only a few bits left to do. still waiting to get rear sets so i can build up the rear brake system.





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post #17 of 61 (permalink) Old 07-20-2016, 06:34 AM Thread Starter
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Re: My SRAD 600 Track Build

I got some standard down pipes from eBay and gave the scrub with the wire brush and applied some rust treatment to them. The treatment changes colour to purple/blue when its reacting with the rust so as you can see it had quite a bit of work to do

looking at the tail end of the pipe i'm not sure if that is standard and thinking that previous owner may have had another section tig welded on. either way i like that chrome look.







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post #18 of 61 (permalink) Old 07-20-2016, 07:01 AM Thread Starter
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Re: My SRAD 600 Track Build

brake system to be installed



Lever, master cylinder, reservoir and brake lines installed. installing the ignition barrel from the SRAD to the K6 fits but not perfect with both both screws. the offset for the screws is slightly different so just ended up using one screw to clear the gap between the frame and the barrel. I'm wanting to upgrade to keyless ignition later on so if anyone knows about how to do this please let me know.



I bought some hose clamps for the brake lines from my local DIY shop and they fit perfect, I really like the clean look and the fact the lines wont be rubbing together.




So far I have got to this stage. The front wheel is the damaged wheel but i just sat it on the axle to see what the bike will look like. For any one who wants to know. The SRAD fron wheel fits perfect in the k6 forks, just make sure you have the k6 spindle and the spacer that goes in between the fork foot and the wheel bearing.




I'm really happy with how it's turning out and will post more images as I progress further. Shouldn't be too long now...he says!

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post #19 of 61 (permalink) Old 07-20-2016, 07:15 PM Thread Starter
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Re: My SRAD 600 Track Build

Had the front wheel and calipers sandblasted today. I have sent the wheel off for powder coating and the calipers i will paint myself with VHT paint.





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post #20 of 61 (permalink) Old 07-20-2016, 07:35 PM Thread Starter
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Re: My SRAD 600 Track Build

Quote:
Originally Posted by tatersalad314 View Post
Are you going to replace the fork internals? What about the rear shock?
The fork internals I have been left standard at the moment but they have been fully overhauled.

The rear shock has just come back from being serviced and now have an Ohlins spring for my weight along with fresh Ohlins fluid.
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