01/06 YZF R1 hybrid

[Carbonar1]

My 01 R1 ate its own gearbox 3 days before christmas last year, so I stuck it in the back of the shed. I've finally decided to get on with rebuilding it, and removed the donk. I also have a pile of leftover OEM 06 R1 bits, and I thought I'd see what I could use, to modernise the old girl.

To start with, the steering head bearings are the same, so the 06 triple clamps will fit straight in. This will reduce the offset and quicken the steering. The 06 forks and wheel will have to go in too...





At this stage I've discovered that the 01 ignition barrel is considerably smaller than the 06 one, which contains wiring for the immobiliser. And the ignition barrel mounts, on the underside of the 06 top yoke, need 5mm trimming off for the 01 steering lock to work.

I have Graves +50mm clip ons I can use with the 06 master cylinder, resevoir, 01 switchchgear and throttle tube.




An 06 clutch perch, which the 01 clutch switch bolts to. And some faded, but swapped and turned upsidedown, CRG levers. ( They're universal, only the silver part changes.)

[Carbonar1]

Next step is the wheel and brakes....







The 01 mudguard has a different bolt spacing, luckily I have an 06 guard that has a disc lock shaped crack in it...Now I put a spraycan lid with DISC LOCK written on it, over the ignition barrel, when I put my babies to bed!

With the 06 yokes as a starting point, there were no dramas with the front end at all!

Then came the rear end...

Upon first measurement, everything looks suspiciously similar! The shocks are the same length, the spacers the same width, and the bolts the same size.



Upon installation, I've discovered that the resevoir has 27mm of clearance before it hits the swingarm. And the shock has 65mm of travel, so the 06 shock fits, but won't work in the 01 chassis. BUGGER!

[Carbonar1]

The 06 footpeg hangers have the same bolt spacing as the 01!



So my old, purple-ish Graves rearsets will fit. And the 01 master cylinder fits on the 06 rearsets, using the 01 bolts.



The shift rod passes through the frame, but I don't know if it will meet up with the shift arm, until I put the motor back in...



The 06 rear wheel fits on the 01 axle, but niether caliper hanger fits straight in. The 01 hanger puts the caliper inside the hub too far. The 06 hanger fits inside the slot in the swingarm, but is 8mm too narrow to fill the space.





Maybe, if I get another chain adjuster block, weld it to the 06 hanger, then machine it down to fit, the hanger wil fit the offset slot in the swingarm.

[vbroom]

cool nice way of restoring an older bike by sticking updated parts in!

[Sentry]

I'd be very interested to see if the rearsets match up perfectly with the shifting rod. I need some new rearsets and can't find anything decent for the 98 R1. Great work!

[Xuaxace]

Awesome, good to see a use the box of "old" parts for something productive

[Carbonar1]

There are some Over rearsets on US ebay at the moment.... By the look of the angle of the shift rod, in comparison to the angle of the hole through the frame, I might need to dog-leg the shift rod a bit, to make it end up at the right spot. I won't know till I fix the gearbox, which I'm avoiding 'cause I can't get the fucking flywheel off, to reveal the bolts, to split the cases. FFFFFFFFFUUUU!

[Carbonar1]

I had a bit of a think about the caliper hangers, at 4am! Insomnia rocks

I thought I might have a look at the 01 wheel spacers in the 06 wheel, and see what difference it makes...
It turns out, that the 01 cush drive side spacer, fits perfectly in the brake side 0f the 06 wheel. And lets the 01 caliper hang in nearly the right spot.

01 brake side spacer on the left - 06 cush drive side spacer on the right.


The 01 hanger with the 06 spacer


The 01 hanger with the 01 spacer...in the 06 wheel...with the 01 dust seal and the 01 axle!


I took this opportunity to service the 01 rear brake, paint the faded blue spot (well I can't very well have shiny gold spot fronts, with a shitty old blue spot rear, can I ?). And fit the 06 resevoir, with some leftover Brembo clear hose.

Before


After...notice the 2.5mm "spacers" between the caliper and hanger, needed to corectly centre the disc in the caliper.




And here she is...01 chassis, 06 wheels and discs, triple clamps and forks, mudguard, radial brakes and lines, master cylinder and resevoirs, clutch perch, clip ons, levers and footpegs.


WOOOHOOO

[Sentry]

Nice work Just out of interest, how did you get the motor out without it smashing into the ground?

[djt77]

Nice work dude