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Swingarm extention basics
- rslingshot
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www.kzrider.com/forum/11-projects/390747-1977-kz1000-new-life
2000 Kawasaki ZRX1100
2004 Gsx-r 750
78 kz1000 basket case
81 yamaha xs 650 basket case
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- rslingshot
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The busa arm is a little differnt than most arms because it is angled 5 degrees from the center of the arm to the top and bottom so you need to match that angle or it will look like crap.
When I know the arm is going on a bike that will truely be at the dragstrip, I will pocket out the back side of the inserts to reduce some of the weight and it keeps me from drilling and taping into a blind hole for the adjuster screw.
You dont have to do this it just helps with the weight after all they ar solid blocks. Tomorrow I will set up and finish the ends,drill and tap the adjuster holes and get ready to weld it up.
www.kzrider.com/forum/11-projects/390747-1977-kz1000-new-life
2000 Kawasaki ZRX1100
2004 Gsx-r 750
78 kz1000 basket case
81 yamaha xs 650 basket case
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- wireman
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posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.
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- testarossa
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I'm surprised that the adjuster blocks don't fit further into the arm than 1/4". I guess it works. You don't see rear wheels falling off Hayabusas. Not too many bikes that can put 'em to a test more than a Busa.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
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- rslingshot
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testarossa wrote: Awesome post. Thanks for taking the time to detail the steps. I know full well that this really slows down progress.
I'm surprised that the adjuster blocks don't fit further into the arm than 1/4". I guess it works. You don't see rear wheels falling off Hayabusas. Not too many bikes that can put 'em to a test more than a Busa.
Thanks Josh, hopefully this will answer some questions or help the guys who have the skill level but just aren't sure of all that is envolved.
You would be shocked at some of the welds that are on factory arms and what they let go on the assembly line.
www.kzrider.com/forum/11-projects/390747-1977-kz1000-new-life
2000 Kawasaki ZRX1100
2004 Gsx-r 750
78 kz1000 basket case
81 yamaha xs 650 basket case
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- jus1975
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I would assume that if you where doing a whole arm that you wouldnt worry about that angle.
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- rslingshot
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After that I started the final prep work on the swingarm, this is a very important because the arrm must be clean clean clean!!!! I start off buy washing the swingarm extentions with simple green or dawn dish washing soap this will remove any oils left from the maching process, then I check to make sure the swingarm legs are the same length,an easy way to do this is to stand the arm on end and lay a strait edges or something flat across the top and measure to it from the floor up.
Then I start grinding the champer on the edges of the swingarm ends, I grind at least 1/4 back on about a 45 degree until you get a knife edge on the end of the arm.
Then you can fit your extention ends into the arm, you want a tight fit this helps hold the ends square and true to the arm.
Then I use a s.s. wire brush on a die grinder this will strip off the factory anodizing on the hayabusa swingarm and it leaves it clean for a good surface to weld to.
Once you are sure everything is good install the extentions in the arm and clamp one side of the swingarm with some c clamps and some thick flat steel. Now you can do this arm and most of the suzuki arms like this because both sides of the swingarm legs come out of a bend and go strait back unlike most of the other sportbike arms out there. You wil need a fixture or a jig for most of the kawasaki's yamaha's and honda's but the suzuki's are pretty easy.
Now you are ready to start welding,first you will need to preheat the swingarm extentions and only the extentions with a torch evenly because of the thickness of the swingarm verses the extention blocks this will make them flow together even.
Then tack the arm while it is clamped up in 4 places and weld across the bottom,then remove the top clamp and block and weld the top and repete the process for the outside of the arm and the inside.
Then do the other side the same way and you should be good.
www.kzrider.com/forum/11-projects/390747-1977-kz1000-new-life
2000 Kawasaki ZRX1100
2004 Gsx-r 750
78 kz1000 basket case
81 yamaha xs 650 basket case
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- rslingshot
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I bend the tubing on the exhaust side 60 degrees and then 30 degrees this gives me clearence for a sidewinder pipe that most of these guys are running, once you have your brace bent and your top plate made you need to preheat the extention blocks again so the blocks will flow at the same rate as the tubing when welding the two together.
And that is just about it, you should have something that looks like this when done.
www.kzrider.com/forum/11-projects/390747-1977-kz1000-new-life
2000 Kawasaki ZRX1100
2004 Gsx-r 750
78 kz1000 basket case
81 yamaha xs 650 basket case
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- z1kzonly
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Brings back memories of "Puppet" in his shop, making his own parts. Before CNC machines
Nice bead of weld too!
Your gonna get a lot of guys PM ing you for work.
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Went thru 25 of these in 40 yrs.
I SOLD OUT! THE KAW BARN IS EMPTY.
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- T_Dub
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1977 KZ650B1
-810cc
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- rslingshot
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T_Dub wrote: I like it. However, I have one question. 6061-T6 is heat treated as we know. When you weld it it, don't you ruin the heat treatment to some extent? How do you combat this? Or do you feel it's necessary?
I have never had any problems. But I will say this years ago I was welding most all my swingarms with er5356 filler rod but I was fighting porosity and some cold cracking, Then I spoke to a rep at a welding supply house in orlando and he told me to try er4043 And it worked out real well for me 4043 has a little less tensile strength but it flows better and you get better penetration, and it is not as prone to cold cracking.
www.kzrider.com/forum/11-projects/390747-1977-kz1000-new-life
2000 Kawasaki ZRX1100
2004 Gsx-r 750
78 kz1000 basket case
81 yamaha xs 650 basket case
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