FZR600 Front End on Seca2 - with Pics!

So after laboriously trying to track down all the parts necessary, I finally succeeded in gathering the proper parts, minus a front fender. Thats mainly because I can't decide if I want to do a FZR600 stock fender, or upgrade to the 1998 R1 front fender (swoops down and wraps around forks for a sleeker look).

Parts:

2003 Yamaha R1 Front Brake System (Calipers, master cylinder, lever)
Two SB8125L Speed Bleeders for R1 Brake System
1997 Yamaha FZR600 Front Wheel / axle / rotors
1994 Yamaha FZR600 Front Triple Trees
1998 Yamaha FZR600 Front Forks
1998 Yamaha FZR600 Fork Brace
8 oz Jug of Belray Dot 4 Brake Fluid
16 oz Can of Belray Brake and Parts Cleaner

As far as front brake system, I opted for the R1 calipers since they have the gold star covers over the calipers. The R6 ones will work just as well, only they have a blue star cover. But when you buy these...ENSURE...I repeast...ENSURE they are not the radial mount calipers. They have to be pre-2003 calipers and mount like mine look.


Injuries Resulting from Swap:

Massive/Deep cut on Palm of right hand from breaking a 6mm hex wrench. Apparently, that one bolt was so cross threaded, I ended up just cutting it off.



Process:

I woke up early at 5am to beat the heat. I started wrenching at 5:30am after I moved everything I needed out to the street. Basically, it went like this:

-Remove front wheel
-Remove front forks
-Remove headlight / headlight tabs / clip-on bars and set aside.
-Remove upper triple clamp

-Install FZR600 front forks
-Install FZR600 front wheel
-Install R1 calipers
-Align everything up, and torque to specs, ensuring all throttle/brake/other cables are not interfering with each other
-Install Speed Bleeders
-Figure out Speed Bleeders
-Get mad, strain back too much, and go lay down in grass for 10min
-Think through the process, and retry
-Speed Bleeders installed, time to start bleeding left side
-Bleed left side until tiny bubbles are coming out of speed bleeder
-Bleed right side until tiny bubbles are coming out of speed bleeder
-Repeat left and right sides until clear, bubble free fluid comes out
-Top off brake fluid and toss out old/new fluid

Take it for a test ride, check the brakes, making sure everything clears, and then take pictures! I am trying to figure out where to mount the front master cylinder, but I figure I've got a little while to figure that out. The MC is full of fluid and is mounted in such a way that it won't get any air sucked into the lines if it tilts down a bit (but is not actually bolted to anything yet).

I am still trying to figure out how I want to mount the instrument cluster, and if I want to bring back my front double bubble fairing. I liked the look of it, but for some reason, without the screen, the bike looks a lot more appealing to me.

I finished the project up around 11am, with a single 30 minute trip to the hardware store. So in total, around a 5.5 hour project...but worth every minute and seemed to only take 2 hours since I started so early!

Here's a few pics:













Results:

I have to say, I can definitely tell a major increase in braking power. In fact, its so much that I have to adjust the lever so it is closer to my hand so I don't over squeeze. I don't want to do an endo when I'm only trying to stop at a red light.

I need to swap my brand new front tire from my old rim to the new rim. The tires are the exact same size, but once I need a new front tire, I will upsize to a 120, so it will be easier/cheaper to replace.

I plan sometime this winter on purchasing stainless steel brake lines for both front and rear and install them. I have to say though, that after installing the speed bleeders, I will never, NEVER pay someone to bleed my brakes again. They are amazingly easy to use, and its pretty self-explanatory as well. On top of that, they are only $7 a piece!

 

Very cool upgrade!

 

I am in love with that bike. I wish I could find a cheap Seca around. I will probably end up getting one soon.